PLC and SCADA training
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SOFCON INDIA PVT. LTD.1
contentsCompany ProfileIndustrial Automation PLC SCADA2
Sofcon Group Companie sSofcon India Pvt. Ltd. Sofcon Systems India Pvt. Ltd. Absolute Control & Auto. Pvt. Ltd. Sofcon Africa Ltd.
Location In India
Industrial Automation Training Courses
PLC & SCADA training courses Motion Control(Drives and Motors) Panel Designing & Auto Cad Process Instruments HMI(human machine interface) DCS training course Industrial networking6
Facilities for Live Exposure
Achievements Till-dateTrained more than 6500 Engineering fresher's/ Working professionals on different automation systems. Placed 4500+ candidates of Sofcon Mod1 (IAE) Training program. Conducted 150+ colleges training programs. Conducted 100+ customized training programs for corporate groups, a few names include IGL, Glaxo smith Kline, Ultratech Cement, Bajaj Auto, Schenk Rotek, McCain Foods, Moser Baer, JCT Electronics, CCIL, JP Groups Etc.8
What is Automation ?Making products under the control of computers and programmable controllers. Automation solutions are required from agricultural to space technology. Plant Automation is the necessity for the manufacturing industry to survive in todays globally competitive market.10
Why Automation required in Industry ?Productivity
Manufacturing Competitiveness Solution
History of Automation
Programmable Logic Controller Hard wired logic Control Manual Control
the actions related to process control are taken by the operators. Drawbacks Likely human errors and consequently its effect on quality of final product. The production, safety, energy consumption and usage of raw material are all subject to the correctness and accuracy of human action.14
Hard wired logic controlThe
Contactor and Relays together with hardware timers and counters were used in achieving the desired level of automation . Drawbacks Bulky panels Complex wiring Longer project time Difficult maintenance and troubleshooting15
MAJOR PARTS OF AUTOMATION
Programmable Logic Controllers
Introduction of PLCPLC is a solid state device or mini industrial computer that performs discrete or sequential logics in a factory environment. It was originally developed to replace mechanical relay, timers, counters. PLCs are successfully used to execute complicated control operations. Its purpose to monitor crucial parameters & adjust process operation accordingly.
Advantages of PLCOn
line/Off line modification Ease of maintenance Large quantity of contacts Greater life & reliability Tremendous flexibility Shorter project time Easier storage and documentation
TYPES OF PLC
Small modular PLC
mounted on rail, 24V supply cheaper not water-proof I/0 can be expanded
Monolithic (one-piece) construction Fixed casing Fixed number of I/O (most of them binary) No process computer capabilities22
P L C Components
Input Output Modules Central Processing Unit Power Supply Bus system Programming Device
P L C Working
Input DevicesPushbuttonsSelector Switches Photoelectric Sensors Proximity Sensors Relay Contacts25
Output DevicesValves Solenoids Lights Horns Meters
Matching the Digital and Analog world
P L C : Power SupplyThe power supply gives the voltage required for electronics module (I/O Logic signals, CPU, memory unit and peripheral devices) of the PLC from the line supply.
The power supply provides isolation necessary to protect the solid state devices from most high voltage line spikes. As I/O is expanded, some PLC may require additional power supplies in order to maintain proper power levels.28
Configuration Of PLC : Allen Bradley
PLC in Cabinetcpu1 redundant field bus connection cpu2
serial connectionsredund. field bus
Hardware over view of PLC
PLC Program ScanSelf Check Scan Inputs
SCAN RATE/SCAN TIME
Scan Cycle Depends upon no. of I/Os
More I/Os More scan timeApplication Decides the Scan time of a PLC Scan time in normal applications is 1 ms to 2 ms & in bigger applications 100 ms to 200 ms33
Troubleshooting in PLC
LED1 LED2 LED3 LED4 LED5
DC power ON Processor fault Memory fault I/O fault Stand by battery low34
Various Brands Of PLC
Allen Bradley Siemens Modicon Mitsubishi GE Fanuc Omron
USA Germany France Japan USA Japan35
Application Of Automation
Ladder is widely used language & is close to Electrical basics. In 50-60% places in a ladder: NO, NC (XIC, XIO in case of Allen Bradley) are used.
It is true when input status is 1
It is true when input status is 0
Supervisory Control & Data Acquisition Systems
SCADA It works like a supervisor who supervises the entire plant area. From a distant place if we want to run the process i.e. starting , stopping. SCADA software is to be connected to PLC / PID / DCS systems which in turn are connected to field instruments. where a person cant be send regularly but process has to be watched continuously.44
Features of SCADA Dynamic process graphic Real-time and Historical trending Alarms Recipe Management Security Device connectivity Script for logic development Networking45
Dynamic Process Graphics Using this feature, one can develop graphics which can resemble the plant. The graphics can include Reactors, valves, pumps, agitators, conveyors as well as other equipment and machinery used in the plant. The status of the equipment running / stopped can be shown using different colours / animation.
Typically the SCADA software will have many ready to use symbols for proper representation which can be used in any type of industry.46
Real-time & Historical Trends
This facility is used for representing the data in graphical form.
Typically the trends plots the value with reference to the time.
Alarms Every plant needs proper monitoring and control of the process parameters.
Alarms represent warnings of process conditions that could cause problems, and require an operator response Generally alarms are implemented by using the lamps or hooters in field but in SCADA it can be represented using animation.48
The recipe management is facility used for maintain various recipes of different products and implement it on the process. 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.
To avoiding access.
Depending upon the access level given the operator / engineers is allowed to do the task. The security can be given for individual as well as for groups.
The SCADA software needs device driver software for communication with PLC. More the driver software available better is the device connectivity.
Scripts Script is a way of writing logic in SCADA software. Using scripts applications. one can develop complex
Various types of scripts make project execution simpler for programmer.
Example of SCADA
Usefulness of SCADA
Production Dept. Quality Dept. Maintenance Dept. Engineering Dept. Manufacturing Dept.
Some of the Leading SCADA SoftwareWonderware : InTouch Intellution : iFix (Earlier Fix DMACS) Allen Bradley : RS View (Earlier Control View) Siemens : WinCC (Earlier Coros LS /B ) GE Fanuc : Cimplicity
Typical Industry Application
Apart from manufacturing process, SCADA software are being used very effectively in water supply and management. The functionality includes.57
Typical Industry ApplicationControl of Substations Load shedding Metering Downtime analysis Dispatch and assessment