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Implementation of control and SCADA system: Case study of Allen Bradley PLC by using WirelessHART to temperature control and device diagnostic
(2022-04-01)
Thepmanee, Teerawat
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Pongswatd, Sawai
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Asadi, Farzin
;
Ukakimaparn, Prapart
System integration for process automation promoted the technologies that were accessed to functions and data of field device, controller, and SCADA system. In addition, the data from filed devices can apply to solve device diagnostic and preventive maintenance. This paper describes the practical technique to configure and implement of control and SCADA system that focus on integration of field device, PLC controller, and SCADA system. The paper presents case study of Allen-Bradley (AB) PLC by using WirelessHART device to temperature control and device diagnostic through SCADA system. PLC's input/output (I/O) modules are installed that consists of Modbus module, digital I/O module, analog I/O module. In addition, Prosoft configuration builder and Studio 5000 software are new software to build add on Modbus instruction and ladder diagrams, respectively. The experiments perform in case study of temperature control by using Proportional–Integral–Derivative (PID) function in the AB PLC. Wonderware InTouch SCADA software is implemented to monitor the process mimic, trend, and alarm. Moreover, the technique can support the operators and engineers to make decision for process control and devices diagnostic.
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Hmi implementation using radar chart for dual-loop system
(2019-08-01)
Pongswatd, Sawai
;
Smerpitak, Krit
;
Kummool, Sart
This article presents a method to implement the Human Machine Inter-face (HMI) for providing high visibility of dual-loop system to encourage good operations and maintenance practices. The proposed method is based on the employment of radar chart to display key performance metrics of simultaneous and independent control of two identical loops for extensive event monitoring. Two level control loops utilizing two Proportional-Integral-Derivative (PID) function blocks of a single Programmable Logic Controller (PLC) are used as the case study to show the workability of the proposed HMI implementation. Each loop consists of a transmitter for measuring the controlled level an inverter for inverting the PLC output to adjust a pump speed, and a power meter form easuring the pump power consumption. The transmitter outputs from both control loops are applied to the PLC analog input module, and then separately scaled to be available to each PID block. The PLC analog output module is used to pass the PID block outputs for manipulating inlet flow rates. The performance metrics including the set point, process variable, manipulated variable, and pump power consumption of both control loops are detected and collected by the HMI/Supervisory Control and Data Acquisition (SCADA)station. All detected data of four performance metrics are represented on the axes of radar chart in real time by using the Wonder ware In Touch software. The script functions to save and load the specified data to the SQL server database are also created on the HMI/SCADA station. Experimental results confirm that the proposed HMI implementation can function correctly.
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Applying radar chart for process control behavior
(2018-06-08)
Pongswatd, Sawai
;
Smerpitak, Krit
This paper presents the technique to show the controller parameters value that can support decision making of controller action and instruments, actuator operation. In addition, energy consumption is detected of any points of process operation. The paper describes method to detect and collect the assigned process control parameters from process components then display their parameters by radar chart. All of assigned parameters are used to construct the plotted of radar figure. The paper designs background and foreground by representation with rectangular array and length of each spoke in radar chart is proportional to magnitude of set value(SV), manipulate value(MV), process value(PV) of PID controller parameters. In addition, watt power (W) of energy consumption in the process is detected and stored. Each spoke of radar chart represents each parameter that converts to scale as 0-100%. The script functions are developed at the SCADA (Supervisory Control and Data Acquisition) station to detect, collect and scale, then store detected parameters in database. The experiments perform in case study of level loop control of water tank processes by using a proportion-integral-derivative (PID) function in the Programmable Logic Controller (PLC) and Wonderware InTouch SCADA software. The technique can apply for exiting SCADA to create the radar chart. Nevertheless, the new version of SCADA software can support the feature but it depends on cost license fee. Moreover, the technique can support the operators and engineers to make decision of process devices performance (instrument, actuator, controller), process operation and condition.
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Integration of wireless HART network system into SCADA software for operation & management
(2016-11-18)
Pongpipatpakdee, Pornchai
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Thepmanee, Teerawat
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Pongswatd, Sawai
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Rerkratn, Apinai
This paper describes the technique to integrate HART field devices into SCADA (Supervisory Control and Data Acquisition) system. Wire HART field device is connected to WirelessHART adapter (THUM) and WirelessHART device are assigned act as RTU(Remote Terminal Unit) in SCADA system. In system, THUM and WirelessHART device communicate to WirelessHART gateway that collects their data and send to master station with Modbus/TCP. The paper presents the practices to install and configure the THUM with control valve wire HART device, WirelessHART transmitter, tags assignment, and so on that focus for HART parameters mapping in order to device operation and management. Effectiveness of the proposed system integration is verified by simulation and experimental results. Moreover, the technique can be applied in existing plants or in new project to support end-users to quickly and easily gain the benefits of device diagnostic and decision support for operation and management.
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Real-time monitoring and reporting alarm system for pH measurement in wet scrubbers
(2016-01-24)
Promsawat, Thipichpon
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Kummool, Sart
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Pongswatd, Sawai
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Julsereewong, Amphawan
In order to improve a maintenance of wet scrubber operation for achieving harmful and polluting gas removal efficiency at a latex glove manufacturer in Thailand, this paper presents a technique to implement the real-time monitoring and reporting alarm system for pH measurement in wet scrubbers. All pH meter outputs are applied to an existing programmable logic controller (PLC) slave located on the master-slave network for production line control. A PLC master is communicated to an operator workstation running the supervisory control and data acquisition (SCADA) software. In addition, measurement data from the SCADA software are automatically transferred to the statistical process control (SPC) software installed in a data historian server. Traditional routine manual data collection and non real-time email notification are replaced by the proposed system, which provides the continuous automatic data collection as well as the real-time display and alarm functions. The automatic and reliable email notification in real time can be also obtained. Experimental results verifying the performance of the proposed system are also included.
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Integration of wirelesshart into scada system and information applications
(2016-01-01)
Wanmahajai, Chaiyan
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Thepmanee, Teerawat
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Pongswatd, Sawai
This paper presents a technique to integrate WirelessHART ﬁeld devices into SCADA (Supervisory Control and Data Acquisition) system. The proposed technique is based on the use of WirelessHART gateway to function as a Modbus/TCP-based RTU (Remote Terminal Unit) of the SCADA hardware architecture for data communications between the remote wireless site and master station. The master station in the studied SCADA system is composed of a computer with ‘Wonderware HMI (Human Machine Interface)/SCADA’ and ‘Historian Client’ software applications. Methods for conﬁguring the software applications used are described. Based on the ‘Wonderware System Platform’, applications of collected and analyzed data for status and event monitoring are also proposed. Eﬀectiveness of the proposed system integration is veriﬁed by experimental results.
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Using wired hart and wirelesshart together for PLC and SCADA system
(2015-01-01)
Thepmanee, Teerawat
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Pongswatd, Sawai
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Kummool, Sart
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Subpayasomboon, Siramet
Wireless Technology has promoted in the process automation because it does not require power and communication wiring for field instruments that enables reduced engineering cost. At the same time, end-users consider the developments of process automation by using wireless devices due to the growing of the new plants and replacing analog or wired HART plants. The paper presents a technique to modify wired HART device to be WirelessHART device and to configure it for communication with other WirelessHART devices. A PLC (Programmable Logic Controller) and SCADA system is used to provide centralized device information, historian, and HMI. Installation and configuration techniques of wired HART, THUM adapter or repeater, WirelessHART, HART gateway are described. In addition, engineering and SCADA software are assigned based on OPC to share WirelessHART data with gateway, PLC and SCADA system. The experimental results by using S7-300 Siemens PLC, WW InTouch, and HART devices in level process control are included to confirm the system workability. Moreover, the technique could be applied to collect data for end-user support to quickly and easily gain the benefits of device diagnostic and to decide the plant operation and planning.

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