International Journal of Innovative and Emerging Research in Engineering

Volume 2, Issue 3, 2015

Available online at www.ijiere.com
International Journal of Innovative and Emerging
Research in Engineering
e-ISSN: 2394 - 3343 p-ISSN: 2394 - 5494

Automation of Chemical Process Plant based on

PLC & SCADA
Priyanka R.Patela, Drashti D.Patelb, Amardeep Singh Bunetc
Student of Electronics & Communication GEC/GTU Bharuch, Gujarat, Indiaa,b.
Director of MICRO SYSTEMS/plot no:4312,Nr. Crystal chowkdi , GIDC, Ankleshwar, Gujarat, India.c

ABSTRACT:
This paper gives information about automation of process plant based on PLC&SCADA. In this plant ammonia
is separated from industrial sludge to protect environment from pollution. The objective of this project is to
convert the manually operated plant to fully automated plant for achieving higher accuracy, efficiency and time
saving. Project uses PLC & configuration software to collect various intelligent instruments on site and
electrical parameters of devices and SCADA for monitoring plant.

Keywords: Automation, PLC, SCADA, Ammonia Separation,

I. INTRODUCTION
To overcome the demand for high quality, high efficiency and automated machines has increased in the industrial sector
of different plants. Many plants require continuous monitoring and inspection at frequent intervals[4]. There are
possibilities of errors at measuring and various stages involved with human workers [4] .Thus this paper takes a sincere
attempt to explain the advantages the companies will face by implementing automation into them.
The process control of distillation which is the most important process in any plant like color industries and its automation
is the precise effort of this paper. In order to automate a plant and minimize human intervention, there is a need to develop
a SCADA (supervisory control and data acquisition) system that monitors the plant and helps to reduce the errors caused
by humans [3]. While the SCADA is used to monitor the system, PLC (programmable logic controller)is also used for the
internal storage of instruction for the implementing function such as logic, sequencing, timing, counting and arithmetic to
control through digital or analog input/ output modules various types of machines processes [3]. Systems are used to
monitor and control a plant or equipment in industries such as telecommunications, water and waste control, energy, oil
and gas refining and transportation[3].

Plant process
In our project distillation process is used for separation of ammonia from industrial sludge. Ammonia is separated to
decrease the hazardness of ammonia from the sludge to save the environment from the pollution.
Control parameters in process
Flow control
Pressure control
Temperature control
Level control
Pressure difference control

1. PLC FOR PLANT CONTROL

PLC stands for programmable logic control. A PLC is a microprocessor-based control system, designed for automation
processes in industrial environments [2]. It uses a programmable memory for the internal storage of user-orientated
instructions for implementing specific functions such as arithmetic, counting, logic, sequencing, and timing. A PLC can
be programmed to sense, activate, and control industrial equipment and, therefore, incorporates a number of I/O points,
which allow electrical signals to be interfaced [1]. Input devices and output devices of the process are connected to the
PLC and the control program is entered into the PLC memory. PLCs programming is based on the logic demands of input
devices and the programs implemented are predominantly logical rather than numerical computational algorithms [1].

How PLC Work????

PLC works mainly in three steps as following.

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 International Journal of Innovative and Emerging Research in Engineering
Volume 2, Issue 3, 2015

Check input status

Execute program

Update output status

CHECK INPUT STATUS

At first the PLC checks each of its input with intention to see which one has status on or off. Means it checks whether a
switch or a sensor etc., is activated or not. The information that the processor thus obtains through this step is stored in
memory in order to be used in the following steps.

EXECUTE PROGRAM
After that PLC executes a program instruction by instruction based on the program and based on the status of the input has
obtained in the preceding step, and appropriate action is taken. The action might be activation of certain outputs and the
results can be put off and stored in memory to be retrieved later in the following steps.

UPDATE OUTPUT STATUS

At last PLC checks up output signals and adjust it has needed. Changes are performed based on the input status that had
been read during the first step and based on the result of the program execution in step two following execution of step
three PLC returns a beginning of the cycle and continually repeats these steps.

Scanning time = Time for performing step 1+ Time for performing step 2+ Time for performing step 3.. [3]

2. SCADA FOR MONITORING PLANT

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 [3] . It is used to monitor and control plant or equipment. The control may be
automatic or initiated by operator commands.
SCADA provides several unique features that make it a particularly good choice for many control problems. The
features are as follows:
A. The computer control primary equipment, record an store a very large amount of data from process.
B. The operator can incorporate real data simulations into the system.
C. The operator is assist by computer that recommend actions to keep the system safety.
D. Many types of data can be collected from the plc, this creates online the image of the System.

3. BLOCK DIAGRAM

SCADA(supervisory control and OPC SERVER

data acquisition)

FIELD INSRUMENTS PLC

(SENSORS,CONTROLLERS...)
(Programmable logic controller)

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Volume 2, Issue 3, 2015

This block diagram shows that whole system is depends on the mentioned blocks.
Field instruments sends reading to SCADA system.
SCADA system reads the measured value send the set points to PLC.
It provides communication between SCADA screen and PLC.
PLC is used for automation of electrical and mechanical process.

OUR SCADA SCREEN SCREENSHOTS

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ADVANTAGES AND DISADVANTAGES OF THE PLC AND SCADA SYSTEM

The advantages of the PLC and SCADA system are:

The computer can record and store a very large amount of data
The data can be displayed in any way the user requires
Thousands of sensors over a wide area can be connected to the system
The operator can incorporate real data simulations into the system
Many types of data can be collected from the PLCs
The data can be viewed from anywhere, not just on site

The disadvantages are:

The system is more complicated than the sensor to panel type.
Different operating skills are required, such as system analysts and programmer
With thousands of sensors there is still a lot of wire to deal with
The operator can see only as far as the PLC

CONCLUSIONS
By using automation based on PLC &SCADA we can increase productivity & replace humans in task done in
dangerous environment. Benefit of replacing human in plant reduce operation time & increase consistency of output.

ACKNOWLEDGMENT
We are thankful to our external guide Mr. Amardeep Singh & Micro Systems company for him guidance and
support throughout the year. His support and encouragements made the project successfully with an appealing concept of
current system. We would like to thank Professor K. G. Bhuva, HOD of the Department of electronics & communication
Engineering, The Government College for providing us the necessary facilities. Also we express our gratitude to all staff
members of Department of Electronics & communication Engineering. We are thankful MICRO SYSTEMS company
Staff they give us good support.

REFERENCES
[1] Sagar P. Jain, Dr. Sanjay L. Haridas ," Energy Efficient Automized Botteling Plant Using PLC And Scada With
Speed Variable Conveyor Assembly"-IOSR Journal of Electronics and Communication Engineering (IOSR-
JECE) ,Volume 9, Issue 1, Ver. II (Jan. 2014)
[2] Mrs. Bhavna Pancholi, 2Damor Mehul Manubhai," Scada Based Power Control System Using PLC"-International
Journal of Scientific Engineering and Technology ,Volume No.3 Issue No.9, Sep 2014
[3] S.T.Sanamdikar and Vartak C ," Color making and mixing process using PLC"-International Journal of Emerging
Trends & Technology in Computer Science (IJETTCS), Volume 2, Issue 5, September October 2013
[4] H. P. Patil1, C. K. Satpute2, S. S. Vaishampayan3, Dr. A.D. Rahulkar," CONTROL OF BOILER OPERATION
USING PLC-SCADA"- International Journal For Technological Research In Engineering ,Volume 1, Issue 7,
March-2014
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