ADVANCED PROCESS CONTROL AND AUTOMATION USING SCADA

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1 ADVANCED PROCESS CONTROL AND AUTOMATION USING SCADA A THESIS Submitted By MODI PANDU RANGA PRASAD (Regd.No:M060307EE) Work carried out at Sree Rayalaseema Alkalies and Allied Chemicals Limited Gondiparla (vi.), Kurnool In partial fulfillment of the requirements for the award of the degree of MASTER OF TECHNOLOGY IN ELECTRICAL ENGINEERING (Computer Controlled Industrial Power) Under the guidance of Dr. M.V.VAIDYAN & Sri P.SRINIVAS REDDY DEPARTMENT OF ELECTRICAL ENGINEERING NATIONAL INSTITUTE OF TECHNOLOGY CALICUT NIT CAMPUS P.O, CALICUT KERALA, INDIA MAY 2008.

2 DECLARATION I hereby declare that this submission is my own work and that, to the best of my knowledge and belief, it contains no material previously published or written material which has been accepted for the award of any other degree or diploma of the university or other institute of higher learning, except where due acknowledgment has been made in the text. Place: NIT Calicut Date: Signature: Name: Modi Pandu Ranga Prasad Reg.No: M060307EE

3 CERTIFICATE This is to certify that the thesis entitled: ADVANCED PROCESS CONTROL AND AUTOMATION USING SCADA submitted by Mr. M.PANDU RNGA PRASAD to the National Institute of Technology Calicut towards partial fulfillment of the requirements for the award of the Degree of Master of Technology in Electrical Engineering (Computer Controlled Controlled Industrial Power) is a bonafide record of the work carried out by him under my supervision and guidance. Dr. M.V.Vaidyan Professor Department of Electrical Engineering National Institute of Technology Calicut Dr.Paul.K.Joseph Professor and Head Department of Electrical Engineering National Institute of Technology Calicut Sri P.Srinivas Reddy Sr.General Manager (Inst) Sree Rayalaseema Alkalis & Allied Chemicals Limited Gondiparla (v); Kurnool District Place: NIT Calicut Date:

4 ON LETTER PAD CERTIFICATE This is to certify that the project entitled, ADVANCED PROCESS CONTROL AND AUTOMATION USING SCADA. submitted by MODI PANDU RANGA PRASAD bearing registration number M060307EE for the award of Master of Technology in Electrical Engineering (Computer Controlled Industrial Power), from NATIONAL INSTITUTE OF TECHNOLOGY CALICUT, is a bonafide work carried out by him under my guidance from June 2007 to April 2008.His performance during the period was excellent and exemplary. Sri.P.Srinivas Reddy Sr.General Manager (Inst.) Sree Rayalaseema Alkalies & Allied Chemicals Limited.,

5 ACKNOWLEDGEMENTS I wish to express my sincere thanks and gratitude towards my internal guide Dr.M.V.Vaidyan, Professor, Electrical Engineering Department, for his excellent guidance and to Professor & Head, Electrical Engineering Department, National Institute of Technology Calicut, for his constant encouragement and help throughout the project. I wish to avail this opportunity to express my thanks to Sri. T.G.Venkatesh, Managing Director, Sree Rayalaseema Alkalies & Allied Chemicals Limited for permitting me to do this project work. I am extremely thankful to Sri Prahaladha Shetty, Manager, HRD for giving me an opportunity to do a project in Sree Rayalaseema Alkalies & Allied Chemicals Limited. I express my heartfelt gratitude and respect to Dr.S.Ashok, Assistant Professor, Electrical Engineering Department, NITC, for his timely advice and guidance while pursuing this project. I am grateful to my external guide Sri P.Srinivas Reddy, Senior General Manager, Instrumentation Department for guiding me successfully through this challenging project and to Sri A.Jaya Narayana, Vice President, Electrical and Instrumentation Department, Sree Rayalaseema Alkalies & Allied Chemicals Limited., for his constant encouragement and help throughout the project. I wish to thank all the Electrical & Instrumentation Department Staff in SRAAC Ltd., for their help and guidance in understanding the subject and invaluable guidance in the technical aspects of the project. Place:Calicut Date: MODI PADU RANGA PRASAD

6 CONTENTS Page No. Abstract i List of Figures ii List of Tables iii List of Symbols iv List of Abbreviations v Chapter 1: Introduction Description Block Diagram Explanation of Each Block Literature Survey Thesis Overview 7 Chapter 2: SCADA-Practical Approach Data Acquiring Data Processing Data Conversion Data Manipulation Data Transmission or Communication 12 Chapter 3: Embedded System PIC Micro Controller Peripheral Features General Features Design Features 18 Chapter 4: Hardware Components Max Power supply Personal computer Signal conditioning circuit Relays 29

7 Chapter 5: Digital PID Controller Block Diagram Micro Controller Address Decoder Circuit ADC Interfacing DAC Interfacing & Signal Conditioning LCD Interfacing LED Bar Graph Interfacing Serial Communication 52 Chapter 6: DAC Circuit Diagram I/V Converter Voltage Follower 56 Chapter 7: Embedded Program VB Program 58 Chapter 8: Pictorial Representation Of Output Chapter 9: Conclusions 82 References 83

8 ABSTRACT This project plays major role in most of the industries nowadays like petrochemical, Cement, sugar and process industries. The main objective of this project is to expose the use of SCADA in a chemical process industry in collecting the data and manipulating it and providing effective, meaningful human communication along with fastest speed. This provides individual measurement and controlling without disturbing other channel data. Automatic channel failure Systems are available called channel in redundancy that provides non-failure operation of the process which in turn increases the on - line, minimum failure and safe operation. In this project, systems are designed to identify the failures of transducers and sensors. This is achieved using advanced linear electronic components and employing VB6 Software. Animations and annunciations are carried out to identify problematic areas and they are removed/replaced at fastest speed. The variables of the process area are recorded for future diagnostic purpose thereby avoiding continuous failures and providing trouble free operation. Globalization requires compatibility on networking. The system is implemented by IBM computer with latest software compatibility and Hardware elements. The PID control action can be implemented as an electronic controller, pneumatic controller and digital controller. We have chosen to implement a microcontroller based PID controller. Unlike analog controllers, digital controllers offer more flexibility since the only changes needed to be made are software changes. The microcontroller is a central processor which regulates the entire operation of the controller. The PID control action is implemented as an algorithm and this control program is run by the microcontroller. Another objective of the project is to achieve process control by implementing the PID algorithm using the microcontroller. The Universal Digital PID Controller, an embedded system, is a single loop, stand alone controller designed for controlling any process and also offers data logging facilities.

9 1.1 DESCRIPTION CHAPTER 1 INTRODUCTION The process of acquiring data from different parameters and taking corresponding supervisory control action in order to maintain a constant output according to the set point given in the P.C by the user is called SCADA. The working of SCADA for instrumentation involves obtaining the different parameters that are to be measured and to be monitored directly through the system after being converted in to analog signal with help of different transducers. In order to measure different types of outputs, different types of transducers are used. The output of transducer will be in the in order of (4-20) ma current, which is standard signal. The output of transducer, which is in the form of analog signal, is being applied to I/V converter. The I/V converter is used in order to convert (4-20) ma signal into corresponding milli volts voltage signal and this milli volts variation cannot be identified by the embedded controller, so we go for amplification by means of signal conditioner circuit. This milli volts signal is applied to signal conditioner circuit in order to boost milli volts to regarding (0-5) volts signal. The reason for converting into (0-5) volts voltage signal is that the P.I.C 16F877A cannot respond to the changes in the current signal, but it can react to the corresponding changes in the voltage signal and before applying to P.I.C 16F877A, filter is used to remove ripples, noise and unwanted signal. The output of (0-5) volts is applied to P.I.C 16F877A.The P.I.C consists of built in RAM, ROM, ADC, USART, PWM & configurable ports. The ADC will convert analog signal into digital signal, as the computer can understand machine level language i.e. 0 and 1 only. Now the data that is being acquired from different parameters are in the form of digital data and the digital data is transmitted using RS 1

10 232C serial communication port to the USER P.C where we can monitor all the data of different parameters. In order to visualize the different control actions that are taking place at the field through animations in the PC we are going to use VB6 software and write a program. Here in the window or applet it consists of a set point box in which we will give a required set point and in order

EMBEDDED SYSTEM DESIGN FOR A DIGITAL MULTIMETER USING MOTOROLA HCS12 MICROCONTROLLER

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