PLC SCADA

Programmable logic controllers (PLCs) have been an integral part of factory automation and industrial process control for decades. PLCs control a wide array of applications from simple lighting functions to environmental systems to chemical processing plants. These systems perform many functions, providing a variety of analog and digital input and output interfaces; signal processing; data conversion; and various communication protocols. All of the PLC's components and functions are centered around the controller, which is programmed for a specific task.

The basic PLC module must be sufficiently flexible and configurable to meet the diverse needs of different factories and applications. Input stimuli (either analog or digital) are received from machines, sensors, or process events in the form of voltage or current. The PLC must accurately interpret and convert the stimulus for the CPU which, in turn, defines a set of instructions to the output systems that control actuators on the factory floor or in another industrial environment

1. Copyright © Appin Technology Lab

2. Copyright © Appin Technology Lab

3. 2Copyright © Appin Technology Lab
•Introduction of PLC
•Introduction of Scada
•What is PLC
•Importance of PLC
•How PLC works
•What is Scada
•Importance of Scada
•How Scada works
•Components of SCADA
•Scada Architectures
•Why Plc-Scada
•Benefits Of PLC-Scada
•Scope of PLC- Scada
TABLEOF CONTENT

4. 3Copyright © Appin Technology Lab
INTRODUCTION OF PLC
Programmablelogiccontrollers(PLCs)havebeenanintegralpartoffactory
automationandindustrialprocesscontrolfordecades.PLCscontrolawidearrayof
applicationsfromsimplelightingfunctionstoenvironmentalsystemstochemical
processingplants.Thesesystemsperformmanyfunctions,providingavariety
ofanaloganddigitalinputandoutputinterfaces;signalprocessing; dataconversion;
andvariouscommunicationprotocols.AllofthePLC'scomponentsandfunctions
arecenteredaroundthecontroller,whichisprogrammedforaspecifictask.
ThebasicPLCmodulemustbesufficientlyflexibleandconfigurabletomeetthe
diverseneedsofdifferentfactoriesandapplications.Inputstimuli(eitheranalogor
digital)arereceivedfrommachines,sensors,orprocesseventsintheform
ofvoltageorcurrent.ThePLCmustaccuratelyinterpretandconvertthestimulusfor
theCPUwhich,inturn,definesasetofinstructionstotheoutputsystemsthat
controlactuatorsonthefactoryfloororinanotherindustrialenvironment.

5. 4Copyright © Appin Technology Lab
INTRODUCTION OF SCADA
SCADA(SupervisoryControlandDataAcquisition)
NowadaysautomationsystemcontainsPLCsandSCADAsoftware.IfyouusePLC&
SCADAcombinationtheadvantagesyouhaveisyouhavebettermonitoringand
controloftheplantandalsoyouhaveaccesstotheinformationthewayyouwant.
SCADAenablesengineers,supervisors,managersandoperatorstoviewandinteract
withtheworkingsofentireoperationsthroughgraphicalrepresentationoftheir
productionprocess.
SCADArunsonaPCandisgenerallyconnectedtovariousPLCsandotherperipheral
devices.Itenablesyoutogenerateapplicationsforthemostdemanding
requirementsofplantengineers,operators,supervisorsandmanagerstailored
preciselytotheneedsofeachplant.SCADAconstantlygathersdatafromtheplant
inreal-time,storesandprocessesitinthedatabase,evaluatesandgenerates
alarms,displaysinformationtoplantoperators,supervisorsandmanagersandcan
issueinstructionstoPLCsontheplantfloor.

6. 5Copyright © Appin Technology Lab
PLC: A PROGRAMMABLE LOGIC
CONTROLLER
AProgrammableLogicController,orPLC,ismoreorlessasmallcomputer
withabuilt-inoperatingsystem(OS).ThisOSishighlyspecializedtohandle
incomingeventsinrealtime,oratthetimeoftheiroccurrence.
ThePLChasinputlineswheresensorsareconnectedtonotifyuponevents
(e.g.temperatureabove/belowacertainlevel,liquidlevelreached,etc.),
andoutputlinestosignalanyreactiontotheincomingevents(e.g.startan
engine,open/closeavalve,etc.).

Thesystemisuserprogrammable.Itusesalanguagecalled"RelayLadder"
orRLL(RelayLadderLogic). Thenameofthislanguageimpliesthatthe
controllogicoftheearlierdays,whichwasbuiltfromrelays,isbeing
simulated.

7. 6Copyright © Appin Technology Lab
IMPORTANCE OF PLC
ThePLCisprimarilyusedtocontrolmachinery.Aprogramiswrittenforthe
PLCwhichturnsonandoffoutputsbasedoninputconditionsandthe
internalprogram.Inthisaspect,aPLCissimilartoacomputer.However,a
PLCisdesignedtobeprogrammedonce,andrunrepeatedlyasneeded.In
fact,acraftyprogrammercoulduseaPLCtocontrolnotonlysimpledevices
suchasagaragedooropener,buttheirwholehouse,includingswitching
lightsonandoffatcertaintimes,monitoringacustombuiltsecuritysystem,
etc.

Mostcommonly,aPLCisfoundinsideofamachineinanindustrial
environment.APLCcanrunanautomaticmachineforyearswithlittle
humanintervention.Theyaredesignedtowithstandmostharsh
environments.

8. 7Copyright © Appin Technology Lab
HOW PLC LOOKS

9. 8Copyright © Appin Technology Lab
HISTORY OF PLC
Whenthefirstelectronicmachinecontrolsweredesigned,theyusedrelaysto
controlthemachinelogic(i.e.press"Start"tostartthemachineandpress"Stop"to
stopthemachine).Abasicmachinemightneedawallcoveredinrelaystocontrolall
ofitsfunctions.Thereareafewlimitationstothistypeofcontrol.
Relaysfail.
Thedelaywhentherelayturnson/off.
Thereisanentirewallofrelaystodesign/wire/troubleshoot.
APLCovercomestheselimitations,itisamachinecontrolledoperation.
Recentdevelopments

PLCsarebecomingmoreandmoreintelligent.InrecentyearsPLCshavebeen
integratedintoelectricalcommunications(Computernetwork)i.e.,allthePLCsinan
industrialenvironmenthavebeenpluggedintoanetworkwhichisusually
hierarchicallyorganized.ThePLCsarethensupervisedbyacontrolcentre.There
existmanyproprietarytypesofnetworks.OnetypewhichiswidelyknownisSCADA
(SupervisoryControlandDataAcquisition).

10. 9Copyright © Appin Technology Lab
PLC: A PROGRAMMABLE LOGIC CONTROLLER

11. 10Copyright © Appin Technology Lab
HOW PLC WORKS
HowthePLCoperates:ThePLCisapurpose-builtmachinecontrol
computerdesignedtoreaddigitalandanaloginputsfromvarioussensors,
executeauserdefinedlogicprogram,andwritetheresultingdigitaland
analogoutputvaluestovariousoutputelementslikehydraulicand
pneumaticactuators,indicationlamps,solenoidcoils,etc.
Scancycle:Exactdetailsvarybetweenmanufacturers,butmostPLCsfollow
a'scan-cycle‘sformat.
OverheadincludestestingI/Omoduleintegrity,verifyingtheuserprogram
logichasn'tchanged,thatthecomputeritselfhasn'tlockedup(viaa
watchdogtimer),andanynecessarycommunications. Communicationsmay
includetrafficoverthePLCprogrammerport,remoteI/Oracks,andother
externaldevicessuchasHMIs(HumanMachineInterfaces).

12. 11Copyright © Appin Technology Lab
InputscanA'snapshot'ofthedigitalandanalogvaluespresentattheinput
cardsissavedtoaninputmemorytable.LogicexecutionTheuserprogram
isscannedelementbyelement,thenrungbyrunguntiltheendofthe
program,andresultingvalueswrittentoanoutputmemorytable.Output
scanValuesfromtheresultingoutputmemorytablearewrittentothe
outputmodules.Oncetheoutputscaniscompletetheprocessrepeats
itselfuntilthePLCispowereddown.

Thetimeittakestocompleteascancycleis,appropriatelyenough,the
"scancycletime",andrangesfromhundredsofmilliseconds(onolderPLCs,
and/orPLCswithverycomplexprograms)toonlyafewmillisecondson
newerPLCs,and/orPLCsexecutingshort,simplecode.
HOW PLC WORKS

13. 12Copyright © Appin Technology Lab
SCADA
(SUPERVISORY CONTROL AND DATA ACQUISITION)
SCADAisasystemoperatingwithcodedsignalsovercommunication
channelssoastoprovidecontrolofremoteequipment(usingtypicallyone
communicationchannelperremotestation).Thesupervisorysystemmay
becombinedwithadataacquisitionsystembyaddingtheuseofcoded
signalsovercommunicationchannelstoacquireinformationaboutthe
statusoftheremoteequipmentfordisplayorforrecordingfunctions.Itisa
typeofindustrialcontrolsystem(ICS).Industrialcontrolsystems
arecomputer-basedsystemsthatmonitorandcontrolindustrialprocesses
thatexistinthephysicalworld.SCADAsystemshistoricallydistinguish
themselvesfromotherICSsystemsbybeinglarge-scaleprocessesthatcan
includemultiplesites,andlargedistances.

14. 13Copyright © Appin Technology Lab
SCADA
(SUPERVISORY CONTROL AND DATA ACQUISITION)

15. 14Copyright © Appin Technology Lab
IMPORTANCE OF SCADA
Scadaprocessesincludeindustrial,infrastructure,andfacility-based
processes,asdescribedbelow:
Industrialprocessesincludethoseofmanufacturing,
production,powergeneration,fabrication,andrefining,andmayrun
incontinuous,batch,repetitive,ordiscretemodes.
Infrastructureprocessesmaybepublicorprivate,andincludewater
treatmentanddistribution,wastewatercollectionandtreatment,oil
and gas pipelines, electrical power
transmissionanddistribution,windfarms,civildefensesirensystems,
andlargecommunicationsystems.

Facilityprocessesoccurbothinpublicfacilitiesandprivateones,
includingbuildings,airports,ships,andspacestations.Theymonitor
andcontrolheating,ventilation,andairconditioningsystems
(HVAC),access,andenergyconsumption.

16. 15Copyright © Appin Technology Lab
SCADA TOOL
SCADAcanbeagreattoolwhileworkinginanenvironmentwhere
operationaldutiesneedtobemonitoredelectronicalcommunication
insteadoflocally.Forexample,anoperatorcanpositionavalvetoopenor
closedasdesiredthroughSCADAwithoutleavingthecontrolstationorthe
computer.TheSCADAsystemalsoallowstoswitchapumpormotoronor
offandhasthecapabilityofputtingmotorsonaHandoperatingstatus,off,
orAutomatic.Handwouldbereferringtooperatetheequipmentlocally,
andautomaticwouldbescalingtheequipmenttobeoperatedaccordingto
setpointstheoperatorinstructsonacomputerthatcancommunicatewith
theequipmentthroughSCADA.

17. 16Copyright © Appin Technology Lab
COMPONENTS OF SCADA
Remoteterminalunits(RTUs)connecttosensorsintheprocessandconvert
sensorsignalstodigitaldata.Theyhavetelemetryhardwarecapableof
sendingdigitaldatatothesupervisorysystem,aswellasreceivingdigital
commandsfromthesupervisorysystem.RTUsoftenhaveembedded
controlcapabilitiessuchasladderlogicinordertoaccomplishbooleanlogic
operations.

Programmablelogiccontroller(PLCs)connecttosensorsintheprocess
andconvertingsensorsignalstodigitaldata.PLCshavemoresophisticated
embeddedcontrolcapabilities,typicallyoneormoreIEC61131-
3programminglanguages,thanRTUs.PLCsdonothavetelemetry
hardware,althoughthisfunctionalityistypicallyinstalledalongsidethem.
PLCsaresometimesusedinplaceofRTUsasfielddevicesbecausetheyare
moreeconomical,versatile,flexible,andconfigurable.

18. 17Copyright © Appin Technology Lab
AtelemetrysystemistypicallyusedtoconnectPLCsandRTUswithcontrol
centers,datawarehouses,andtheenterprise. Examplesofwiredtelemetry
mediausedinSCADAsystemsincludeleasedtelephonelinesandWAN
circuits.ExamplesofwirelesstelemetrymediausedinSCADAsystems
includesatellite(VSAT),licensedandunlicensedradio,cellularand
microwave.
Adataacquisitionserverisasoftwareservicewhichusesindustrial
protocolstoconnectsoftwareservices,viatelemetry,withfielddevices
suchasRTUsandPLCs.Itallowsclientstoaccessdatafromthesefield
devicesusingstandardprotocols.

Ahuman– machineinterfaceorHMIistheapparatusordevicewhich
presentsprocesseddatatoahumanoperator,andthroughthis,thehuman
operatormonitorsandinteractswiththeprocess.TheHMIisaclientthat
requestsdatafromadataacquisitionserver.
COMPONENTS OF SCADA

19. 18Copyright © Appin Technology Lab
AHistorianisasoftwareservicewhichaccumulatestime-stamped
data,booleanevents,andbooleanalarmsinadatabasewhichcanbe
queriedorusedtopopulategraphictrendsintheHMI.Thehistorianisa
clientthatrequestsdatafromadataacquisitionserver.
Asupervisory(computer)system,gathering(acquiring)dataontheprocess
andsendingcommands(control)totheSCADAsystem.
Communicationinfrastructureconnectingthesupervisorysystemtothe
remoteterminalunits.
Variousprocessandanalyticalinstrumentation
COMPONENTS OF SCADA

20. 19Copyright © Appin Technology Lab
HOW SCADA WORKS
ThetermSCADAusuallyreferstocentralizedsystemswhichmonitorand
controlentiresites,orcomplexesofsystemsspreadoutoverlargeareas
(anythingfromanindustrialplanttoanation).Mostcontrolactionsare
performedautomaticallybyRTUsorbyPLCs.Hostcontrolfunctionsare
usuallyrestrictedtobasicoverridingorsupervisorylevelintervention.For
example,aPLCmaycontroltheflowofcoolingwaterthroughpartofan
industrialprocess,buttheSCADAsystemmayallowoperatorstochange
thesetpointsfortheflow,andenablealarmconditions,suchaslossofflow
andhightemperature,tobedisplayedandrecorded.Thefeedbackcontrol
looppassesthroughtheRTUorPLC,whiletheSCADAsystemmonitorsthe
overallperformanceoftheloop.

21. 20Copyright © Appin Technology Lab
DataacquisitionbeginsattheRTUorPLClevelandincludesmeterreadings
andequipmentstatusreportsthatarecommunicatedtoSCADAas
required.Dataisthencompiledandformattedinsuchawaythatacontrol
roomoperatorusingtheHMIcanmakesupervisorydecisionstoadjustor
overridenormalRTU(PLC)controls.DatamayalsobefedtoaHistorian,
oftenbuiltonacommodityDatabaseManagementSystem,toallow
trendingandotheranalyticalauditing.
HOW SCADA WORKS

22. 21Copyright © Appin Technology Lab
SCADAsystemstypicallyimplementadistributeddatabase,commonly
referredtoasatagdatabase,whichcontainsdataelementscalled
tagsorpoints.Apointrepresentsasingleinputoroutputvaluemonitored
orcontrolledbythesystem.Pointscanbeeither"hard"or"soft". Ahard
pointrepresentsanactualinputoroutputwithinthesystem,whileasoft
pointresultsfromlogicandmathoperationsappliedtootherpoints.(Most
implementationsconceptuallyremovethedistinctionbymakingevery
propertya"soft"pointexpression,whichmay,inthesimplestcase,equala
singlehardpoint.)

SCADAsystemsaresignificantlyimportantsystemsusedinnational
infrastructuressuchaselectricgrids,watersuppliesandpipelines.
However,SCADAsystemsmayhavesecurityvulnerabilities,sothesystems
shouldbeevaluatedtoidentifyrisksandsolutionsimplementedto
mitigatethoserisks.
HOW SCADA WORKS

23. 22Copyright © Appin Technology Lab
SCADA ARCHITECTURE

24. 23Copyright © Appin Technology Lab
Firstgeneration:"Monolithic“
EarlySCADAsystemcomputingwasdonebylargeminicomputers. Common
networkservicesdidnotexistatthetimeSCADAwasdeveloped.Thus
SCADAsystemswereindependentsystemswithnoconnectivitytoother
systems.Thecommunicationprotocolsusedwerestrictlyproprietaryat
thattime.Thefirst-generationSCADAsystemredundancywasachieved
usingaback-upmainframesystemconnectedtoalltheRemoteTerminal
Unitsitesandwasusedintheeventoffailureoftheprimarymainframe
system.SomefirstgenerationSCADAsystemsweredevelopedas"turnkey"
operationsthatranonminicomputerssuchasthePDP-11seriesmadeby
theDigitalEquipmentCorporation
SCADA ARCHITECTURE

25. 24Copyright © Appin Technology Lab
Secondgeneration:"Distributed“
SCADAinformationandcommandprocessingwasdistributedacross
multiplestationswhichwereconnectedthroughaLAN.Informationwas
sharedinnearrealtime.Eachstationwasresponsibleforaparticulartask
thusmakingthesizeandcostofeachstationlessthantheoneusedinFirst
Generation.Thenetworkprotocolsusedwerestillnotstandardized. Since
theprotocolswereproprietary,veryfewpeoplebeyondthedevelopers
knewenoughtodeterminehowsecureaSCADAinstallationwas.Security
oftheSCADAinstallationwasusuallyoverlooked.
SCADA ARCHITECTURE

26. 25Copyright © Appin Technology Lab
Thirdgeneration:"Networked“
Similartoadistributedarchitecture,anycomplexSCADAcanbereducedto
simplestcomponentsandconnectedthroughcommunicationprotocols.In
thecaseofanetworkeddesign,thesystemmaybespreadacrossmore
thanoneLANnetworkandseparatedgeographically.Severaldistributed
architectureSCADAsrunninginparallel,withasinglesupervisorand
historian,couldbeconsideredanetworkarchitecture.Thisallowsfora
morecosteffectivesolutioninverylargescalesystems.
SCADA ARCHITECTURE

27. 26Copyright © Appin Technology Lab
Fourthgeneration:"InternetofThings“
Withthecommercialavailabilityofcloudcomputing,SCADAsystemshave
increasinglyadoptedInternetofThingstechnologytosignificantlyreduce
infrastructurecostsandincreaseeaseofmaintenanceandintegration.Asa
resultSCADAsystemscannowreportstateinnearreal-timeandusethe
horizontalscaleavailableincloudenvironmentstoimplementmore
complexcontrolalgorithmsthanarepracticallyfeasibletoimplementon
traditionalprogrammablelogiccontrollers.Further,theuseofopen
networkprotocolssuchasTLSinherentinInternetofThingstechnology
providesamorereadilycomprehendableandmanageablesecurity
boundarythantheheterogeneousmixofproprietarynetworkprotocols
typicalofmanydecentralizedSCADAimplementations.
SCADA ARCHITECTURE

28. 27Copyright © Appin Technology Lab

29. 28Copyright © Appin Technology Lab
WHY PLC-SCADA
Inrecenttimes,allmosteveryindustryuseautomationorcontrolsystems
forworking.Everyindustryneedsmoreengineerstogrowtheirproduction
rate.Foreigncountrieshavealsounderstoodtheimportanceofautomation.
Itisatypeofcontrolsystemwhichinvolvesinformationtechnologyand
reducesthehumanmanuallyworksinproduction.Forautomationindustry
PLCandSCADAarethemostimportanttools,withoutthesetools
automationisnotpossible.Itplaysavitalroleintheworldeconomyasit
replacesallmanualsystemspower.

Ifyouwanttogetabestjobinautomationindustry,youmusthaveanidea
aboutindustry’srequirement.Almosteveryindustryneedsprofessionally
trainedstudentswhohavesomeexperienceanddetailedknowledgeabout
PLC-Scadatechnology.Candidateneedstogettrainedinthesame,because
Traininghelpsthemtogetpracticalknowledgeandskillsthatrequiredto
getplacedinafamousindustry.Bygettingtrainedwiththeprofessionals
whohaveindustryexperience,youwillgettheindustryexposurewiththe
industrialtrainingprojectaswell.

30. 29Copyright © Appin Technology Lab
WHY APPIN
Ifyouarelookingforabettercareerinanautomationindustryafter
completingyourdegree,Youshouldgettrainedfromthecompanywhohas
expertiseinthesame.Appinisawell-knowncompanyinthefieldof
InformationTechnologywhichprovidesindustrialtrainingforallcourses
relatedtoIT,electronicsandtelecomfield.WealsoprovidestheJob
OrientedTrainingprogramsinInformationSecurity/IRM/Secured
Applicationprogramming/SecuredMobileApplicationDevelopment
programminginAndroid,BlackBerry,iOS.Ourplacementrecordisbetter
thanotherplayersinthemarket.

Ourtrainingprogramsareonthelatesttechnologieswiththeupdated
versions&advancedconcepts.LikecloudcomputingPLC-Scada.

31. 30Copyright © Appin Technology Lab
HOW SCADA LOOKS

32. 31Copyright © Appin Technology Lab
MANUFACTURING INDUSTRIES

33. 32Copyright © Appin Technology Lab
BENEFITS OF PLC- SCADA
PLCandSCADAarethesuccessbehindtheautomationindustry.PLCisdesigned
insuchawaythatitcanbeusedtocontrolmultipleinputsandoutputsandit
canbehandledinextremetemperaturechanges.Withoutthesetwo
automationconceptstheautomationindustryfails.Sothereisahugedemand
forskilledmanpowerinPLCandSCADAinautomationindustry.Wecannoteven
thinkofsurvivingwithoutthistechnologyevenforaday.Ifthesystemfailsthen
therewouldbelossesofcoresofrupees.AftertheapplicationofPLCand
SCADAtechnologyinIndustrialautomationprocess.
Itiscreatingalotofemploymentopportunities
Thereisahugedemandforskilledmanpowerinthissector
Reducestime
ReducesCost
Profitmaximization
Economiesofscale
ImprovedProductivity
Qualityoutput

IncreasedAccuracyandspeed

34. 33Copyright © Appin Technology Lab
SCOPE OF PLC SCADA
IfyouhavePLC-Scadatrainingcertificate,youwillgetachanceindifferent
companiesondifferentprofilesspeciallyinthemanufacturingindustry.
Someoftheprofilesarementionedbelow:-
1.PLC-SCADATrainee
2.PLC-SCADASoftwareEngineer
3.AutomationandDrivesmanufactureratglobalfirms
4.PLCSCADAHMIACDC
5.ApplicationEngineer–PLC-Scada
6.ElectricalMaintenanceautomationManagermaintenance
ManagerPLCSCADA
7.AutomationEngineer.
8.
InstrumentationEngineer.

35. 34Copyright © Appin Technology Lab
COMPANIES HIRING FOR PLC SCADA
and many more….

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For more details please visit:
www.training.appinonline.com
www.appinonline.com

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