1 INTRODUCTION TO AUTOMATION

Automation is the use of control systems such as computers to control industrial

machinery and process, reducing the need for human intervention. In the scope of
industrialization, automation is a step beyond mechanization. Whereas
mechanization provided human operators with machinery to assist them with
physical requirements of work, automation greatly reduces the need for human
sensory and mental requirements as well. Processes and systems can also be
automated.
Automation Impacts:

1. It increases productivity and reduce cost.

2. It gives emphasis on flexibility and convertibility of manufacturing
process. Hence gives manufacturers the ability to easily switch from
manufacturing Product A to manufacturing product B without
completely re-built the existing system/product lines.
3. Automation is now often applied primarily to increase quality in the
manufacturing process, where automation can increase quality
substantially.
4. Increase the consistency of output.
5. Replacing humans in tasks done in dangerous environments.

Advantages of Automation:

1. Replacing human operators in tasks that involve hard physical or

monotonous work. Also task done in dangerous environments.
2. Performing tasks that are beyond human capabilities of size, weight,
speed, endurance, etc.
Economy improvement: Automation may improve in economy of enterprises,
society or most of hum

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Disadvantages of Automation:

1. Technology limits: Current technology is unable to automate all the de-

sired tasks.
2. Unpredictable development costs: The research and development cost of
automating a process may exceed the cost saved by the automation
itself.
3. High initial cost: The automation of a new product or plant requires a
huge initial investment in comparison with the unit cost of the product.

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2 Programmable Logic Controller
A programmable logic controller, PLC is a digital computer used for
automation of typically industrial electromechanical processes, such as control
of machinery on factory assembly lines etc. It is a solid state user
programmable control system with functions to control logic, sequencing,
timing, arithmetic data manipulation and counting capabilities. It can be
viewed as an industrial computer that has a central processor unit, memory,
input output interface and a programming device. The central processing unit
provides the intelligence of the controller. It accepts data, status information
from various sensing devices like limit switches, proximity switches, executes
the user control program stored in the memory and gives appropriate output
commands to devices such as solenoid valves, switches etc.
A constant demand for better and more efficient manufacturing and
process machinery has led to the requirement for higher quality and reliability
in control techniques. With the availability of intelligent, compact solid state
electronic devices, it has been possible to provide control systems that can
reduce maintenance, down time and improve productivity to a great extend.
One of the latest techniques in solid state controls that offers flexible and
efficient operation to the user is programmable controllers.

2.1 Features of PLCS

1. PLC is an industrial computer control system that continuously monitors
the state of input devices and makes decisions based upon a custom pro-
gram to control the state of output devices.

2. It is designed for multiple inputs and output arrangements, extended

temperature ranges, immunity to electrical noise, and resistance to
vibration and impact.
3. Almost any production process can greatly enhanced using this type of
control system, the biggest benefit in using a PLC is the ability to
change and replicate the operation or process while collecting and
communicating vital information.
4. It is modular i.e. one can mix and match the types of input and output
devices to best suit one’s application.

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2.2 History of PLCS
1. The first PLCS were designed and developed by Modicon as a relay re-
placer for GM and Landis.
2. The primary reason for designing such a device was eliminating the
large cost involved in replacing the complicated relay based machine
control systems for major U.S. car manufacturers.
3. These controllers eliminated the need of rewiring and adding additional
hardware for every new configuration of logic.
4. The first PLC, model 084, was invented by Dick Morley in 1969.

5. The first commercial successful PLC, the 184, was introduced in 1973
and was designed by Michel Greenberg.

2.3 Components of PLC:

The PLC mainly consists of a CPU, memory areas, and appropriate circuits to receive
input/output data. We can actually consider the PLC to be a box full of hundreds or
thousands of separate relays, counters, timers and data storage locations. Each
component of a PLC has a specific function:

1. The CPU is the brain of a PLC system. It consists of the microprocessor,

memory integrated circuits and circuits necessary to store and retrieve
information from memory. It also includes communication ports to the
peripherals, other PLCs or programming terminals. The job of the
processor is to monitor status or state of input devices, scan and solve
the logic of a user program, and control on or off state of output devices.
2. Counters - These are simulated counters and they can be programmed to count
pulses. Typically these counters can count up, down or both up and down.
Since they are simulated they are limited in their counting speed. Some
manufacturers also include high-speed counters that are hardware based. We
can think of these as physically existing.

3. Timers - These come in many varieties and increments. The most com-mon
type is an on-delay type. Others include off-delay and both retentive and non-
retentive types. Increments vary from 1 millisecond to 1 second.

Output Relays (coils) - These are connected to the outside world. They physically
exist and send on/off signals to solenoids, lights, etc. They can be transistors, relays
depending upon the model chosen.
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 5. Data Storage - Typically there are registers assigned to simply store
data. They are usually used as temporary storage for math or data
manipulation. They can also typically be used to store data when power
is removed from the PLC. Upon power-up they will still have the same
contents as before power was removed

2.4 PLC OPERATION AND PLC SCAN CYCLE:

There are four basic steps in the operation of all PLCS which continually take
place in a repeating loop.

1. Input Scan: Detects the state of all input devices that are connected to
the PLC.
2. Program Scan: Executes the user created program logic.

3. Output Scan: Energizes or de-energize output devices that are connected

to the PLC. Depending on the PLC design, this process of updating the
output devices may be done at the end of program execution or updated
immediately upon execution of its corresponding logic statement in the
user program
4. Housekeeping: This step includes communications with programming
terminals, internal diagnostics etc.

PLC SCAN CYCLE: The completion of a cycle of the controller is called

a Scan. The scan time needed to complete a full cycle by the controller gives
the measure of the speed of execution for the PLC.

Figure 1: PLC scan cycle

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SCAN TIME: Time taken by PLC to execute these three steps (Checking
Input status, Executing Program, Updating Output Status) is denoted by its
scan time.

2.5 Ladder Logic

Ladder logic is one form of drawing electrical logic schematics, and is a
graphical language very popular for programming PLCS. Ladder logic was
originally invented to describe logic made from relays. The name is based on
the observation that programs in this language resemble ladders, with two
vertical ”rails” and a series of horizontal ”rungs” between them.

Figure 2: Basic Ladder Logic Program

2.6 Ladder Logic Programming

Introduction
Ladder logic are the most common programming language used to
program a PLC. Ladder logic was one of the first programming approaches
used in PLCS because it borrowed heavily from the relay diagrams that plant
electricians al-ready knew.
A program in ladder logic, also called a ladder diagram, is similar to a
schematic for a set of relay circuits. Ladder logic is widely used to program
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 Figure 3: Basic Ladder Logic Program

PLC’S, where sequential control of a process or manufacturing operation is

required. Ladder logic is useful for simple but critical control systems, or for
reworking old hardwired relay circuits. As programmable logic controllers
became more sophisticated it has also been used in very complex automation
systems .A simplified ladder logic circuit with one input and one output. The
logic of the rung above is such:

Figure 4: Basic Program to show input and output

1. If Input1 is ON (or true) - power (logic) completes the circuit from the
left rail to the right rail - and Output1 turns ON (or true).
2. If Input1 is OFF (or false) - then the circuit is not completed and logic
does not flow to the right - and Output 1 is OFF (or false).

With just a handful of basic symbols such as a normally open contact,

normally closed contact, normally open coil, normally closed coil, timer and
counter most logical conditions can be represented.
Examine if Closed

Figure 5: Examine if Closed

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This can be used to represent any input to the control logic such as a switch or
sensor, a contact from an output, or an internal output. When solved the
referenced input is examined for a true (logical 1) condition. If it is true, the
contact will close and allow logic to flow from left to right. If the status is
FALSE (logical 0), the contact is open and logic will NOT flow from left to
right.
Output energize
This can be used to represent any discrete output from the control logic.
When ”solved” if the logic to the left of the coil is TRUE, the referenced
output is TRUE (logical 1).

Figure 6: Output energize

Examine if open
When solved the referenced input is examined for an OFF condition. If the
status is OFF (logical 0) power (logic) will flow from left to right. If the status
is ON, power will not flow.

Figure 7: Examine if open

Basic Timers and Counters

A timer is simply a control block that takes an input and changes an output
based on time. It is used for providing delay. There are two basic types of timers.
An On-Delay Timer takes an input, waits a specific amount of time, allows logic
to flow after the delay. An Off-Delay Timer allows logic to flow to an output and
keeps that output true until the set amount of time has passed, then turns it false,
hence off-delay.
A counter simply counts the number of events that occur on an input.
There are two basic types of counters called up counters and down counters.
As its name implies, whenever a triggering event occurs, an up counter
increments the counter, while a down counter decrements the counter
whenever a triggering event occurs.

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3 SCADA

3.1 Introduction
SCADA stands for Supervisory Control And Data Acquisition. As the name
indicates, it is not a full control system, but rather focuses on the supervisory
level. As such, it is a purely software package that is positioned on top of
hard-ware to which it is interfaced, in general via PLC. SCADA systems are
now also penetrating the experimental physics laboratories for the controls of
ancillary systems such as cooling, ventilation, power distribution, etc. More
recently they were also applied for the controls of smaller size particle
detectors such as the L3 moon detector and the NA48 experiment, to name
just two examples at CERN.
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 as those of physics experiments.
The process can be industrial, infrastructure or facility based as described
below:

1. Industrial Process: it includes those of manufacturing, production,

power generation, fabrication and refining and process may be in
continuous, batch, repetitive or discrete modes.
2. Infrastructure Process: it may be public or private, and water treatment
and distribution, wastewater collection and treatment, oil and gas
pipelines, electrical power transmission and distribution, and large
communication systems.

3. Facility Process: it occur both in public facilities and private ones,

including buildings, airports, ships and space stations. They monitor and
control HVAC, access and energy consumption.

A SCADA System usually consists of the following Subsystems:

1. A Human-Machine Interface (HMI) is the apparatus which presents

process data to a human operator, and through this, the human operator
monitors and controls the process.
2. A supervisory (computer) system, gathering (acquiring) data on the
process and sending commands (control) to the process.
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 3. Remote Terminal Units (RTU) connecting to sensors in the process,
converting sensor signals to digital data and sending digital data to the
supervisory system.

4. Programmable Logic Controller (PLC) used as field devices because

they are more economical, versatile, flexible, and configurable than
special-purpose RTUs.
5. Communication infrastructure connecting the supervisory system to the
Remote Terminal Units.

3.2 WONDERWARE-INTOUCH
InTouch is worlds leading supervisory control and data acquisition software.
The InTouch software package consist of Tags (Memory + I/O). The package
is available in 64, 256, 1000 and 64,000 Tags with the three options:

1. D+R+N ( Development +Run + Networking)

2. R+N ( Run +Networking )

3. Factory focus

With DRN package one can develop as well as run the application but in case
of RN one cannot develop/modify the application. The application can be
developed by using DRN package and can be installed on RN package.

3.3 Manufacturers of SCADA

1. Allen Bradley : RS View

2. Siemens: win cc

3. Wonderware : Intouch

3.4 Features of SCADA

1. Dynamic Process Graphic

2. Alarm summary

3. Alarm history
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 4. Real time trend

5. Historical time trend

6. Security (Application Security)

7. Data base connectivity

8. Device connectivity

9. Scripts

10. Recipe management

3.4.1 Dynamic Process Graphics

1. Using this feature, one can develop graphics which can resemble the
plant.
2. The graphic can include Reactor, Valves, Pumps, agitators, conveyors as well
as other equipment and machinery used in the plant.

3. The status of the equipment running / stopped can be shown using

differ-ent color / animations.
4. Typically the SCADA Software will have many ready to use symbols for
proper representation which can be used in any type of industry.

Figure 8: Schematic of DPG

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3.4.2 Real-time and Historical Trends

1. This facility is used for representing the data in graphical form.

2. Typically the trends plots the value with reference to the time.

3. Real-time data will plot the real-time value fixed period of time while
historical data stored value which can be viewed on demand.

4. Depending upon the storing capacity of the hard-disk on can specify the
no of days the data can be stored .
5. Some SCADA software show real-time and historical trends in single
graphics while few others use separate tools.

Figure 9: Schematic of Trends

3.4.3 Alarms

1. Every plant need proper monitoring and control of the process parame-
ters.
2. Alarms represent warnings of process conditions that could cause prob-
lems, and require an operator response.

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 3. Generally alarms are implemented by using the lamps or hooters in field
but in SCADA it can be represented using animation.

4. In many SCADA software, four type of alarm limits are used ie HI,
HIHI, LOW, LOW LOW.

Figure 10: Schematic of Alarm

3.4.4 Recipe Management

1. In many case we use the same plant for manufacturing different prod-
uct range. for example an oil blending plant can manufacture power oil,
transformer oil, automobile oil.
2. The recipe management is facility is used to maintain various recipes of
different products and implement it on the process.
3. The recipe can be stored in a single server and it can be fetched by any
client server from any area to run the process.

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Figure 11: Schematic of Recipe management

Figure 12: Recipe manager window

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3.4.5 Security
1. Every SCADA Software has various levels of security for securing the
application by avoiding unauthorized access.
2. Depending upon the access level given the operator / engineers is
allowed to do the task. In the most of the case, operators are allowed
only to operate the plant while maintenance engineers can do the
application modifications.
3. The security can be given for individuals as well as for groups.

Figure 13: Schematic of Security

3.4.6 Device Connectivity

1. Every Control hardware has its own communication protocol for
communicating with different hardware / software. Some of the leading
communication protocol include Modbus, Profibus, Ethernet, Dh+, DH
485, Devicenet, Control net.
2. The Scada Software needs device driver software for communication
with PLC or other control hardware.
3. More the driver software available better is the device connectivity.
Most of the SCADA software used in the industry have connectivity
with most of the leading control system.
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3.4.7 Database Connectivity
1. In many plants, it is important to download the real-time information to
the Management information system. In this case the database
connectivity is must.
2. Many SCADA software don’t have their own database. Hence for
storage and reporting they use third party database like MS Access or
SQL.

3.4.8 Scripts
1. Script is a way of writing logic in SCADA software, every SCADA
soft-ware has its own instruction and way of writing program.
2. Use scripts, one can develop complex applications. You can create your
own functions to suit the requirement. execution.
3. Various types of scripts make project execution simpler for
programmer.

3.5 Potential benefits of SCADA

The benefits one can expect from adopting a SCADA system for the control
of experimental physics facilities can be summarized as follows:

1. The amount of specific development that needs to be performed by the

end-user is limited, especially with suitable engineering.
2. Reliability and robustness: These systems are used for mission critical
industrial processes where reliability and performance are paramount. In
addition, specific development is performed within a well-established
framework that enhances reliability and robustness.
3. Technical support and maintenance by the vendor.

3.6 Where SCADA is used ?

1. Electric power generation, transmission and distribution: Electric
utilities use SCADA systems to detect current flow and line voltage, to
monitor the operation of circuit breakers etc.

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2. Water and sewage: State and municipal water utilities use SCADA to
monitor and regulate water flow, reservoir levels, pipe pressure and
other factors. Industrial Processes such as Manufacturing.

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4 Project Using PLC: Glowing of four LED using
START, STOP and SELECTOR Switches

4.1 Project Objective:

To design a system using Programmable Logic Controller with the

specifications given: There are four LEDs red, green, yellow and blue. Two
push-button switches are there for START, STOP and for LED selection there
is SELECT switch. The START button is pressed after that:

1. Condition 1: If SELECT switch is pressed once then red LED glows.

2. Condition 2: If SELECT switch is pressed twice then green LED glows.

3. Condition 3: If SELECT switch is pressed thrice then yellow LED

glows.

4. Condition 4: If SELECT switch is pressed four times then blue LED

glows.

4.2 Hardware and Software Used:

1. PLC: Allen Bradley Micro Logix 1000 with 10 Input / Output.
The MicroLogix 1000 programmable controller is a packaged controller
containing a power supply, input circuits, output circuits, and a
processor. The controller is available in 10 I/O, 16 I/O and 32 I/O
configurations, as well as an analog version with 20 discrete I/O and 5
analog I/O.

Figure 14: Schematic of PLC-1000 Micrologix

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 2. Programming Software: Rockwell software RS Logix 500 English
This family of products has been developed to operate on Microsoft
Windows operating systems. It Supports the Allen-Bradley SLC 500
and MicroLogix families of processors. RSLogix 500 benefits include:
(a) Cross-reference information
(b) Drag-and-drop editing
(c) Diagnostics
(d) Dependable communications
3. Communication Software: RSLinx.
4. Programming Language: Ladder Logic.
5. Communication Protocol: RS 232
6. Other Hardware: Push Buttons, Light Emitting Diode.

4.3 Working of Project:

Figure 15: Flowchart of Ladder logic

As specified in the objective there are four conditions under which LEDs
of different colors will glow. Once the STOP button is button is pressed the
process will stop. This whole idea is implemented in the ladder logic.

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4.4 Programming:
1. Figure with explanation

Figure 16: Start button is pressed

Rung 0000:

(a) The SELECTOR switch is indicated by I:0/0 which is connected to

four parallel UP counters C5:0(preset = 1), C5:1 (preset = 2),
C5:2(preset = 3),C5:4 (preset = 4). All the counters have their
accu-mulator value set to zero.
(b) These counters work on discrete pulses and count the number of
times the SELECTOR switch is pressed. Each time when the SE-
LECTOR switch is pressed the accumulator value of each counter
is incremented by 1 until the reaches the value of its preset.
(c) When the accumulators value = preset value, the DN bit of the
counter goes HIGH.
2. Figure with explanation
Rung 0001:

(a) The input XIC I:0/1 (START switch) is connected with XIC
C5:0/DN, XIO I:0/2 (STOP switch), XIO C5:1/DN, XIO
C5:2/DN,XIO C5:3/DN and the binary output B3:0/0.
(b) Except C5:0/DN all the DN bits are XIO because the condition 1 is
checked where except C5:0/DN none of the DN bits should be
high.
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 Figure 17: B3:0/0 is high and Red LED glows

(c) The output B3:0/0 is connected as input parallel to I:0/1 to make a

holding circuit, so that even if the START button is released
B3:0/0 remains high.
(d) When the SELECTOR switch is pressed only once, the
accumulator value of all the counters becomes 1 and the C5:0/DN
becomes HIGH. Next when the START switch is pressed then all
the inputs in the rung are HIGH, therefore, the output B3:0/0 will
be energized i.e. it goes HIGH.
Rung 0002:

(a) B3:0/0 is connected as input to the output O:0/0. The output O:0/0
indicates the red LED.
(b) As soon as the B3:0/0 goes HIGH the output O:0/0 is energized.
Hence the output red LED glows.
3. Figure with explanation
Rung 0003:

(a) The input XIC I:0/1 (START switch) is connected with XIC
C5:0/DN, XIO I:0/2 (STOP switch), XIC C5:1/DN, XIO
C5:2/DN,XIO C5:3/DN and the binary output B3:0/0.

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 Figure 18: B3:0/1 is high and Green LED glows

(b) Except C5:0/DN and C5:1/DN all the DN bits are XIO because
here condition 2 is checked where except C5:0/DN and C5:1/DN
none of the DN bits should be high.
(c) The output B3:0/1 is connected as input parallel to I:0/1 to make a
holding circuit, so that even if the START button is released
B3:0/1 remains high.
(d) When the SELECTOR switch is pressed twice, the accumulator
value of all the counters becomes 2. The C5:0/DN and C5:1/DN
becomes HIGH.
(e) When the START switch is pressed then all the inputs in the rung
0003 are HIGH, therefore, the output B3:0/1 will be energized i.e.
it goes HIGH.
(f) Since, XIC C5:1/DN is now HIGH , therefore, XIO C5:1/DN in
rung 0001 goes LOW, therefore, B3:0/0 goes LOW and hence the
red LED stops glowing.
Rung 0004:

(a) B3:0/1 is connected as input to the output O:0/1. The output O:0/1
indicates the green LED.
(b) As soon as the B3:0/1goes HIGH the output O:0/1 is energized.
Hence the output green LED glows.

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4. Figure with explanation
Rung 0005:

(a) The input XIC I:0/1 (START switch) is connected with XIC
C5:0/DN, XIO I:0/2 (STOP switch), XIC C5:1/DN, XIC
C5:2/DN,XIO C5:3/DN and the binary output B3:0/2.
(b) Except C5:3/DN all the DN bits are XIC because here condition 3
is checked where C5:0/DN ,C5:1/DN and C5:2/DN bits should be
high.

Figure 19: B3:0/2 is high and Yellow LED glows

(c) The output B3:0/2 is connected as input parallel to I:0/1 to make a

holding circuit, so that even if the START button is released
B3:0/2 remains high.
(d) When the SELECTOR switch is pressed thrice, the accumulator
value of all the counters becomes 3. The C5:0/DN, C5:1/DN and
C5:2/DN becomes HIGH.
(e) When the START switch is pressed then all the inputs in the rung
0005 are HIGH, therefore, the output B3:0/2 will be energized i.e.
it goes HIGH.
(f) Since, XIC C5:2/DN is now HIGH, therefore, XIO C5:2/DN in
rung 0001 and 0003 goes LOW, therefore, the red and green LED
stops glowing.

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 Rung 0006:

(a) B3:0/2 is connected as input to the output O:0/2. The output O:0/2
indicates the yellow LED.
(b) As soon as the B3:0/2goes HIGH the output O:0/2 is energized.
Hence the output yellow LED glows.
Rung 0007:

(a) The input XIC I:0/1 (START switch) is connected with XIC
C5:0/DN, XIO I:0/2 (STOP switch), XIC C5:1/DN, XIC
C5:2/DN,XIC C5:3/DN and the binary output B3:0/2.
(b) All the DN bits are XIC because here condition 4 is checked where
all DN bits should be high.
(c) The output B3:0/3 is connected as input parallel to I:0/1 to make a
holding circuit, so that even if the START button is released
B3:0/3 remains high.
(d) When the SELECTOR switch is pressed four times, the accumula-
tor value of all the counters becomes 4. The C5:0/DN, C5:1/DN,
C5:2/DN and C5:3/DN becomes HIGH.
(e) When the START switch is pressed then all the inputs in the rung
0007 are HIGH, therefore, the output B3:0/3 will be energized i.e.
it goes HIGH.
(f) Since, XIC C5:3/DN is now HIGH, therefore, XIO C5:3/DN in
rung 0001, 0003 and 0005 goes LOW, therefore, the red, green and
yel-low LED stops glowing.
5. Figure with explanation
Rung 0008:

(a) B3:0/3 is connected as input to the output O:0/3. The output O:0/3
indicates the blue LED.
(b) As soon as the B3:0/3goes HIGH the output O:0/3 is energized.
Hence the output blue LED glows.

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 Figure 20: Counters get Reset

4.5 Results
All the conditions mentioned in the objective are obtained

4.6 Future Scope

1. The project based on glowing different LEDs can be extended in
industry environment for doing different automated tasks by usage of
same set of hardware, just by changing the program or logic stored in
the PLC.

2. If the PLC is connected with SCADA using ”Device Connectivity”

feature, various other features like Recipe Management, Alarms etc. can
be used to make the system more reliable for the industrial environment.

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5 Project Using SCADA: Sewage Water Treatment

5.1 Project Objective:

To design “Sewage Water Treatment System” in Wonderware Intouch SCADA.

5.2 Software Used:

Wonderware Intouch version 9.0
Wonderware is a brand of industrial software sold by Schneider Electric.
Wonderware was part of Invensys PLC, and Invensys PLC was acquired in
January 2014 by Schneider Electric. Wonderware software is used in diverse
industries, including: Facilities Management, Food and Beverage, Mining and
Metals, Power, Oil and Gas, and Water and Waste water. Wonderware
Intouch software is an open and extensible Supervisory HMI and SCADA
solution that enables the rapid creation of standardized, reusable visualization
applications and deployment across an entire enterprise. InTouch SCADA
consists of three major programs:

1. Application Manager,
2. Window Maker
3. Window Viewer

The InTouch Application Manager organizes the applications created by the

user. InTouch Application Manager is used to create new applications, open
existing applications in either WindowMaker or Window Viewer, delete
applications, and run the InTouch DBDump and DBLoad Tagname Dictionary
utility programs. It also is used to configure Window Viewer as an NT
service, to con-figure Network Application Development (NAD) for client-
based and server-based architectures etc.
Window Maker is the development environment, where object-oriented
graphics are used to create animated, touch-sensitive display windows. These
display windows can be connected to industrial I/O systems and other Microsoft
Windows applications.
Window Viewer is the run time environment used to display the graphic
windows created in Window Maker. Window Viewer executes InTouch Quick
Scripts, performs historical data logging and reporting, processes alarm
logging and reporting, and can function as a client and a server for DDE
communication protocols.
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5.3 Working of Project:
The project is made in Window Maker and executed in Window Viewer. In
window viewer, the project would run as:
When the START switch is turned on, water from the storage tank flows
to the sedimentation tank after passing through the screening filter. As soon as
the sedimentation tank is filled the rotator inside the tank is turned on so as to
deposit the sediments at the bottom of the tank. Next, clean water from the
sedimentation tank is transferred to the chlorine tank where the water is
chlorinated to kill the germs and make it fit for drinking. Next, the water is
oxygenated by passing oxygen gas into it in the chlorine tank. The water from
the chlorine tank is filtered and stored in another tank for usage.

5.4 Programming:
1. In the Intouch Application Manager, we select file ! New ! Create new
Application. This creates a new Intouch application.
2. When we double click on this application, it opens Intouch Window
maker.
3. In Window maker we select File !New Window. A dialog box appears
asking for name, window type, window color and other properties.
4. We name the window as ”sewage water treatment”, window type as re-
place, frame style as single and click on OK. A window appears as per
defined by us.
5. Next we click on the wizard icon. The Wizard Selection window
appears in which there are various options of the graphical objects.
6. We select fixture switches from the Switches option of the Wizard
selection window. The rest all other graphical objects will be picked
from the symbol factory option.
7. In the Wizard Selection window, we select symbol factory option and
then double click it. This opens the symbol factory window.
8. In the symbol factory window there are various categories of the
graphical objects like Tanks, agitator wheels etc. We select the different
objects as per our requirement.
9. For all the objects taken from the symbol factory, we perform ”Break
Cell” operation so that we are able to change their properties as per our
requirement Following is the figure showing the list of the properties
available for each object from Symbol Factory:

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 Figure 21: Schematic of Object Properties

10. For our project we require tanks, pipes, valves, agitators etc. these
objects are picked up the symbol factory and other objects like
screening filter etc. are built by us using the basic shapes and some like
the oxygen bubbles and the sediments are picked by performing ”break
symbol” operation on various objects of general manufacturing option
(e.g. coal mining).

11. Next we place the objects as per the setup required for water treatment
and modify the objects property. For example, when water is to be
transferred from one tank to the other the source tank must be full
initially and the liquid level of the source tank should decrease steadily
and water level in the destination tank should increase steadily in the
destination tank.

12. For this we double click on the tank, select “vertical” under ”fill”
option. We give the tag name A and then specify the values of
maximum and minimum fill percentages along with the values of the
’A’.

13. Similarly other properties of the objects are changed.

14. The finished window is shown

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Figure 22: Window in development mode in Window maker

15. We see that we need to use duplicate of the tanks and rotators in case of
sedimentation and oxidation tank because a tank once filled cannot be
emptied and a rotator once rotated cannot be stopped. Hence their
duplicates are used keeping in mind their visibility.

16. Visibility is a property which is required when we want to use the same
properties of an object for more than once with different values of tag
name. In Intouch this is not allowed, therefore we make duplicate of the
object, then modify their properties and apply the visibility property.

17. Visibility comes under the category of miscellaneous property. Other

miscellaneous property which we have used in this project is
”orientation”. We have used this property to show the rotation of the
agitators. Other property called ”blink” is used to show oxygenation of
water by producing blinking effect in the bubbles.
18. Moreover, the pipe color needs to be grey initially, blue when water
passes through it and then again it should be grey. This is done by
applying the property ”analog fill color”. This property enables us to
define color at various break points.
19. Since there is no manual work i.e. no slider is being used, window script
has to be used for incrementing the value of the counter, whose tag
name is used as the expression for all other objects.

20. The script written for this project is shown below:

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 Figure 23: Schematic of Window Script used

(a) There are two parts in the script:

(b) On Show: how the things should appear as soon as the window
viewer is started.
(c) While showing: how things will appear once the task starts to run
on window viewer.
21. As shown in the figure the window script follows simple ”if- else if-
else” with logical operators ”and-or-not”.
22. In the script we can see that the value of A is incremented when its
value is less than 105, the START switch is kept on and the STOP is
off. The increment is done in 1000 millisecond period. This can also be
decreased to increase the speed of execution.
23. As soon as the value of A becomes equal to 105, the value of A is reset
to
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 0 and the process repeats itself in an infinite loop until the STOP switch
is pressed on.

24. Now, we test our project in window viewer. For this we click on ”Run-
time!” icon at the top right corner of the tool bar.
25. This option takes us to the run- time environment. As soon as Window
Viewer is started we see that it follows the instructions of ”On Show”
until the switch is turned on. As soon as the switch is turned on, it
follows the instructions of ”While Showing”.

26. In case we find some anomaly in execution, we need to first switch to

Window Maker for rectifying it. For this we click on the
”development!” icon placed at the top right corner of the Window
Viewer.

27. We can change our script and properties of the various objects used in
Window Viewer but test its execution in Window Maker. The functions
of both are different.
28. The following snapshot shows the execution of the program:

(a) Transfer of sewage water from the storage tank to the

sedimentation tank.

Figure 24: Sedimentation of water

(b) Oxygenation and chlorination of water in the chlorine tank after its
sedimentation

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 Figure 25: Oxygenation and chlorination of water

(c) Chlorinated water is being passed through a filter and stored in an-
other tank for usage.

Figure 26: Passing water through filter

29. This process continues to execute repeatedly until the STOP switch is
turned on.

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5.5 Results
The design of ”Sewage Water Treatment System” is successfully
implemented in Intouch SCADA.

5.6 Future Scope

1. This project can be implemented practically when SCADA is connected
with PLC. More enhanced features can be added up to it. For e.g.
Reverse Osmosis purification system can be added.
2. The project based on sewage can be extended to water purification
systems, oil refinery systems in industries.

3. The project can also be extended to packaged drinking water industries

where water is first purified, then filled into bottles, capped, labeled and
then sold in bottles.

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6 CONCLUSION
With the speed of changing technology today it is easy to lose sight or
knowledge of the basic theory or operation of programmable logic. Most
people simply use the hardware to produce the results they desire. Hopefully,
this report has given the reader a deeper insight into the inner workings of
programmable logic and its role in mechanical operations. The idea of
programmable logic is very simple to understand, but it is the complex
programs that run in the ladder diagrams that make them difficult for the
common user to fully understand. Hopefully this has alleviated some of that
confusion.

SCADA is used for the constructive working, using a SCADA system for
control ensures a common framework not only for the development of the
specific applications but also for operating the detectors. Operators experience
the same “look and feel” whatever part of the experiment they control.
However, this aspect also depends to a significant extent on proper
engineering.

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References
[1] Richard A. Cox, ”Technicians Guide to Programmable Controllers” , 4th
edition, Vikash Publishing House, New Delhi.
[2] J. R. Hackworth, F.D. Hackworth, ”Programmable Logic Controllers
Programming Methods and Applications” Pearson Education, New Delhi

[3] J. W. Webb, R A Reis , ”Programmable Logic Controllers Principle and

Applications” 5th edition, Prentice Hall of India ltd., New Delhi
[4] literature.rockwellautomation.com/idc/groups.

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