A

Project On

Adv. PLC Programming

&

SCADA

To whom it may Concern

This is to certified that Mr. ABHISHEK KUMAR of

B.TECH 4 th Sem of C.T INSTITUTE OF TECHNOLOGY, JALANDHAR had done Excellent

work on project entitled Adv. PLC Programming & SCADA. under guidance and supervision of Mr. Neeraj

Kumar and Mr. Vikash Kumar Singh at MSME TOOL ROOM, (IDTR)_Jamshedpur for the completion of

his one month VOCATIONAL TRAINING in duration of

16-06-2015 TO 15-07-2015 for their college’s curriculum related industrial training. To the best of my knowledge and belief, the same project has not been submitted to any university or institute.

Mr. Vikash Kumar Singh, Mr. R. Das Gupta

Faculty Member Manager Training

PLC Deptt. IDTR, Jamshedpur

IDTR, Jamshedpur

Acknowledgement

I, ABHISHEK KUMAR student of C.T INSTITUTE OF TECHNOLOGY, JALANDHAR Branch ELECTRICALS & ELECTRONLCS 4thSem Wid Reg. no.- 1459202 here by being thankful to MSME TOOL ROOM, Jamshedpur (IDTR) for allowing me to undergo training session of one month, secondary member Mr. Neeraj kumar and Mr. Vikash Kumar Singh, whose guidance allowed me to inherit knowledge, experience and skill during my training period and to all the staff members as well as the course co- ordinator of our Electronics & Electricals Deptt. for their sincere cooperation at every step, lastly to all the Knowledge Centre /members battling to the tough seen which never had been an easy for them but their working and handling things taught me much more than just theoretical knowledge.

I Really Experienced such taughtfull lessons and I feel pride to express sincere gratitude and indebtedness to all who guided us at our each and every step that I could never achieve or could learn under any college curriculum which taught me the real use of our bookish lessons that real applicatins are so vast That only we could know through this training to manage all this Automation engineering.

A project Report on PLC & SCADA

INDEX1) BRIEF CONCEPT ABOUT

AUTOMATION2) INTRODUCTION TO RELAY3) INTRODUCTION TO SOLENOID &

CONTACTOR4) INTRODUCTION TO PLC5) CONCEPT OF NO & NC6) ALLEN BRADLEY SIMULATION

USING LOGIX PRO.a) DOOR SIMULATIONb) SILO SIMULATIONc) TRAFFIC SIMULATION

7) SIEMENS SIMULATION USING S7- 200

8) INTRODUCTION TO SCADA

Brief Concept Of AutomationAutomation is the use of automatic equipment instead of manual labour. A machine working on its own without any manual interface. Automation are of two types:-

1) Home Automation- Using Micro Processors, micro controller & a very

significant device called “Application Specific Integrated Controller” As

(ASIC).

2) Industrial Automation- Using PLC, PAC, HMI, SCADA, VFD.

PLC Stands For Programmable Logic Controller.

PAC Stands For Programmable Automation Controller.

HMI Stands For Human Machine Interface.

SCADA Stands For Supervisory Control & Data Acquisition.

VFD Stands For Variable Frequency Drives.

Industrial Automation Is Further Divided Into Two Parts:-

1) Factory Automation which categories An Automobile Industry and Industries having Machine Automation.

2) Process Automation which categorizes any Chemical Industry or Some OIL & Gas Industries.

INTRODUCTION TO RELAY

A Relay is an Electrical Switching Device invented in 1960. Which can be arranged in circuits to make logical decisions and thus output from this circuit can be used to drive “Loads”, Such as Motors, Heaters, Or any Electro magnetic Coils.

As it is a Switching Drevice It Also acts as a sensing device or basicaaly as a sensor which can sense the flow of current through it in some rapid action as it is an electrical device its working/Operating range is 0-24 v DC and it could switch upto 0-220 v AC.

Use Of Relay:---- Provides Electrical Isolation.--- Very short time on/Off. (Mili/Micro. Sec.)--- Single Pulse Generation.--- High Reliability.--- Fault free.

Fig:- RELAY

INTRODUCTION TO SOLENOID & CONTACTOR

Solenoid:- the most common actuator component whose basic principle of operation that there is a moving ferrous core (a piston) that will move inside the coiled wire. Normally, the piston is held outside the coil by a spring. When a voltage is applied to the coil and current flows through the coil builds up a magnetic field that attracts the piston and pulls it into the center of coil. The piston can b e used to supply the linear force. Well known applications of these are car door openers and the pneumatic valves.

Contactor:- A contactor is an electric device used for controlling of the power flow. It is activated by control input which is the lower voltage/current than that to which the contactor is switching.

Application Of Contactor:-

---it can stand at its own as a power control device or as a part of a starter.

--- it can be used in light switching as well as the most complex auto-mated industrial Equipment.

--- it is also used as the switching device in for frequent actions of on/Off.

A Contactor is Comprised Of three different system:-

---The Contact:- The Current carrying part of the Contactor, including power contact, Auxilliary Contacts & Contact Springs.

---The Electromagnet:- this system provides the driving force to close the contacts.

---The Enclosure:- A frame housing the contacts of the electromagnet.

INTRODUCTION TO PLCIt is a Programmable Logic Controller also used as an industrial Computer Used to monitor inputs and depending upon their state make decision based on its program and logic’s to control its output to automate a machine or a process.

It can also be defined as a digitally operating electronic device which use an programmable.

====PLC Input Devices:- Sensors & Switches (9v, 12v, 24v)

A Sensor is a device that consists of a physical condition into an Electrical signal for use by the PLC.

A Push button can be a Example Working As a Sensor.

----Proximity Sensor

----Capacitive Sensor

----Inductive Sensor

----Optical Sensor

----Limit Switch & Reed Switch is a Mechanical Switch.

====PLC Output Devices:- Actuators Convert an Electrical signal from the PLC into a physical condition. Actuators are connected to the PLC Output. A motor starter is one example of an actuator that is connected to the PLC Output. Depending on the Output PLC signal the motor starter will either start or stop the motor.

Advantages of PLC:-

=It is the central part of the process control system.

=To run Complex machine it is possible to run more PLC with the central Computer.

=Troubleshooting aids make programming easier and reduces the downtime.

=Cost effective for running complex controlling and a reliable component that lasts long.

=Rugged and Designed to with stand Vibrations, Temp., humidity and noise.

=interface is already assigned in the controller.

=Easily programmable and more easily understood programming language.

Disadvantages of PLC:-

=Very Expensive.

=Too much Wire Required.

=Requirement of skillfull worforce.

=A Programming device could be used in a specific brand of PLC.

=Sensitive of heat, dust, moisture, Temp, Pressure.

Application of PLC:-

=PLC can be used in any field where auto-machine is required. Here are few applications of PLC.

=Conveyor System.

=Elevator

=Wood working Machinary

=Packaging Equipment

=Placement System

Types of PLC:- Micro, Mini, and Rack (used in complex industrial work where we could increase or decrease the number of I/O Ports.)

=NANO PLC:- The smallest PLC known till yet which consist of less than 10 I/O Ports.

=MICRO PLC:- Smaller PLC in automation field which consists of 10-15 Input and 10-12 Output ports. The ports depends upon manufacturing company.

=MINI PLC:- Medium size PLC with 100-200 I/O Modules. The modular construction in MINI PLC is 8 or 16 bit.

=RACK PLC:- It consists thousands of Modules as per required. But it consists separate modules.

TYPES OF LANGUAGES USED IN PLC PROGRAMMING

LADDER DIAGRAM (LD) STRUCTURED TEXT (ST) FUNCTION BLOCK DIAGRAM (F.B.D) SEQUENTIAL FUNCTION CHART (S.F.C) INSTRUCTION LIST (I.L)

LADDER DIAGRAM (LD): Ladder logicis a programming language thatrepresents a program by a graphical diagram based on the circuit diagrams of relay logic hardware. It is primarily used to develop software for programmable logic controllers (PLCs) used in industrial control applications. 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. An argument that aided the initial adoption of ladder logic was that a wide variety of engineers and technicians would be able to understand and use it without much additional training, because of the resemblance to familiar hardware systems. Ladder logic is widely used to program PLCs, 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. Often the ladder logic program is used in conjunction with an HMI program operating on a computer workstation.

BASIC PLC OPERATION

BLOCK DIAGRAM OF A PLC

CONCEPT OF NO & NC

Basically the concept of NO and NC must be clear for designing, maintenance of any control of Electrical or PLC. This NO/NC is mainly related to contact points.

NO-Normally open

NC-Normally closed

ELECTRICAL SYMBOL

NORMALLY OPEN NORMALLY CLOSED

SYMBOL FOR PLC PROGRAMMING

Relay Contact Normally Open Relay Contact Normally Closed

NORMALLY OPEN (NO) –which stand for normally open contact. Normallymeans power OFF condition or cold state. Thus any contact, which will be in open condition. When power is OFF, is known as normally open contacts.

This will be closed only when external force is applied (either manual, electrical or by any external means). Only when pushed then A and B get connected. Here control is through manually. Where as in relay or contactor point 3 and 4 closed by giving external voltage (AC & DC) depend upon the coil.

NORMALLY CLOSED (NC) –which stand for normally closed contact.Normally means power OFF condition or cold state. Thus any contact, which will be in closed condition, when power is OFF, is known as normally closed contacts.

This will be open only when external force is applied (either manual, electrical or by any external means) only when pushed then A & B get disconnected here control is through manually, where as in relay or contactor point 3 and 4 opened by giving external voltage (AC & DC) depend upon the coil.

.

INTRODUCTION TO LOGIX PRO. SIMULATION

Introduction to logixpro:-

LogixPro software:-

LogixPro is a PLC simulator that is particularly geared toward Rockwell’s RSLogix 500 software. There is no need for any PLC hardware when using the simulator. The keyed edition of LogixPro, that is part of the course materials, provides animated process simulations, including an I/O simulator with changeable switch types, output indicators, thumbwheel switches and a BCD digital readout. Several process animations are also included and we will be working with several of them in future homework labs.

The LogixPro Interface:-

The LogixPro interface is very similar to the RSLogix 500 interface, so now that you have successfully completed the introduction to RSLogix 500 lab, you should quickly be able to become comfortable in the LogixPro environment.

The adjoining figure shows the LogixPro environment after the software is initially started.

Note the similarities and differences to RSLogix 500. The first obvious difference is that there is a simulation where the project window should be and that there is an animated help wizard on the screen. If you would like to hide the animated help wizard, right click on him and select Hide.

The instruction tool bar is the same as RSLogix 500 except that not all the instructions are available in LogixPro and there is an additional button in the upper right corner. This button is called the toggle button and will toggle the PLC simulator from offline to online mode. Scan through the instruction tabs and observe what is and is not available.

The LogixPro Screen:-

The most commonly used elements of LogixPro are displayed below. The Edit Panel provides easy access to all the RSLogix instructions and they may be simply dragged and dropped into your program. Once program is ready for testing, clicking on the "Toggle Button" of the Edit Panel will bring the PLC Panel into view. From the PLC Panel we can download our program to the "PLC" and then place it into the "RUN" mode. This will initiate the scanning of the program and the I/O of your chosen simulation.

DOOR SIMULATION

PROJECT

If the Door is fully open, the Open lamp will be energized but not flashing.

If the Door is opening, the Open lamp will flash while the door is in motion.

If the Door is fully closed, the Shut lamp will be energized but not flashing.

If the Door is closing, the Shut lamp will flash while the door is in motion.

The Ajar Lamp will glow if door is not in the fully open or fully closed position; it is either in motion or stationary.

Components Description Address

Motor up It helps to move the door up. O:2/00Motor down It helps to move the door down. O:2/01

Limit switch up It becomes active when door is fully I:1/03open.

Limit switch down It becomes active when door is fully I:1/04closed.

Ajar led It glows when door is neither fully O:2/02open nor fully closed

Open led It glows when door is opening or fully O:2/03Open

Shut led It glows when door is closing or fully O:2/04Closed

Open button When pressed, door starts opening I:1/00Close button When pressed, door starts closing I:1/01Stop button When pressed ,the system should stop I:1/02

PROCESS DESCRIPTION

There are total of three switches (open, close & stop) & three L.E.Ds( open, close & ajar).

There are two sensors as well (low level sensor & high level sensor).

When the system is not in run mode both the sensors are in deactivate state.

When start is pressed the motor up gets active. After reaching the upper level limit, the high level sensor activates itself & cut the supply from motor up preventing it from getting burnt.

Likewise when the close button is pressed the motor down gets active & after reaching the lower level limits the low level sensor cut the supply from the motor.

All throughout the process the LEDs reflect the state of the system.

When the door is opening or closing the 'Ajar' glows all throughout the process & the open or close LED blinks respective of the process.

When the door reached the open state or close state the "ajar' stops glowing & the Open or close LED glows respectively.

When stop button is pressed at any point of the process, the entire process stop

SILO SIMULATION

PROJECT

Completely design and de-bug a ladder control circuit which will automatically position and fill the boxes which are continuously sequenced along the conveyor.

The sequence can be stopped and re-started at any time using the panel mounted Stop and Start switches.

The RUN light will remain energized as long as the system is operating automatically.

The RUN light, Conveyor Motor and Solenoid will de-energize whenever the system is halted via the STOP switch.

The FILL light will be energized while the box is filling.

The FULL light will energize when the box is full and will remain that way until the box has moved clear of the prox-sensor.

Components Description Address

Start switch When pressed, bucket I:1/00

moves forward onconveyor belt attached tomotor.

Stop switch When pressed, system I:1/01should stop ,at that state

Run led It will glow as long as O:2/02system is runningautomatically.

Fill led It will glow when bucket O:2/03starts getting filled, assolenoid valve opens.

Full led It will glow as long as O:2/04level sensor remainsactive.

Motor It will help to move O:2/00conveyor belt.

Prox-sensor It will become active I:1/03when right edge ofbucket is in front of itand again deactivatewhen left edge of bucketcrosses it.

Solenoid valve It will become active O:2/01when bucket is in front ofit.

Level sensor It will become active I:1/04when bucket is perfectlyfilled.

PROCESS DESCRIPTION

The system consists of 2 switches (start & stop), 3 LEDs (run, fill &full), 2 sensors (level &prox) and 1 solenoid valve.

When start is pressed the conveyor starts. As the box reaches the filling station the prox-sensor activates.

Prox-sensor cuts the supply from the motor to stop the box at the desired place.

It opens the solenoid valve as well & the box starts to get filled.

Once its full the level sensor activates & closes the solenoid valve to remove the condition of overflow.

It activates the motor again & the box moves out from the filling station.

the entire process until stop is pressed.

The RUN LED glows all throughout the process.

The FILL LED glows when filling process is undergoing & FULL LED will glow when the level sensor senses the box is filled to its maximum value.

TRAFFIC LIGHT SIMULATION

COMPONENTS DESCRIPTION ADDRESS

CROSSWALK When pressed activates I:1/00,I:1/01PUSHBUTTON the processVEHICLE SENSOR It senses the presence of I:1/02,I:1/03

vehicle and becomeactive when vehicle is infront of it

WALK AND DON’T When vehicle is in O:2/03,O:2/07motion on any road, thewalk of same road isactivated, else displaysdon’t

RED LIGHT When glows, not allows O:2/00,O:2/04the vehicle to pass onroad

YELLOW LIGHT When glows, allows the O:2/01,O:2/05vehicle to pass on road

GREEN LIGHT Vehicle is running on O:2/02,O:2/06road only when greenwill glow

PROJECT

Initially red light will glow for 2 sec for both roadways

Vehicle will run on road only for 7 sec till yellow & green light will glow.

Yellow will glow for two seconds & green will glow for 5 seconds. After red yellow & then green will glow for any one road.

After green light of a road yellow light of other road will glow & follow the sequence as before.

The whole system will continuously run once ‘cross walk’ button is pressed.

PROCESS DESCRIPTION

There are total of two switches (start & stop) & eight LEDs (2 red, 2 yellow, 2 green & 2 walk sign)

The signal is been placed at the junction point of two cross roads.

At the beginning red signals of both the side will glow. When start button ll be pressed of one side traffic of that side will be opened.

After sensing the car at the traffic of that side the red signal(1) of that side turns into yellow(1) & car will be passing for 2 sec. after two sec the green(1) light glows & the traffic will pass for 5 sec. All throughout the process the signal (2) on the other side of the road will remain red (2).

After 5 sec the signal 1 automatically turns into red again

& the signal 2 turns into yellow for 2 sec & then green for 5 sec.

The entire process continues in a loop until stop button is pressed.

The walk sign also glows with the yellow of each signal & remain until the signal changes into red again.