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PLC SCADAINDUSTRIAL TRAINING

Submitted by:anmoleceWhat is AUTOMATIONMaking products under the control of computers and programmable controllers is known as automation.Manufacturing assembly lines as well as stand alone machine tools and robotic devices fall into this category.It is delegation of human control functions to technical equipment for increasing the productivity, quality, and increasing the safety in working conditions thereby reducing the manpower and cost.

INSUSTRIAL AUTOMATIONNow a days, every small and large industry employ automation.In manual control, an operator periodically reads the process and adjusts the input accordingly. Quite hectic!In automation control, measurements and adjustments are done automatically on a continuous basis. Quite convenient!

PLC (Programmable Logic Controller)It is microprocessor based solid state/industrial computer that perform discrete or sequential logic.It was developed to replace mechanical relays, timers, counters.The early PLCs were used to reduce the changeover time, wiring/re-wiring.The PLC programming procedures replaced the rewiring a panel full of wires, relays, timers, counters etc. Advantages Reliability in operation.Flexibility in control and programming techniques.Online offline modifications.Small physical size, shorter project time.In house simulation and testing of project.Speed of operation.Ease of maintenance and troubleshooting.Ability to communicate and networking with computer system in plant.Documentation and security.Designed to work in all types of industrial conditions.

Micrologix 1000 programmable controller

Architecture of a PLCPLCOUTPUT DEVICES(Displays & Monitors)INTERFACEMEMORYINPUT DEVICESPOWERSUPPY(SCADA or HMI)(External memory module)(Toggle or Push buttons, proximity or pressure sensors) (24V DC,120V AC)Hardware Overview

DATA TRANSMISSION - SERIAL

SYSTEM(PORT) PLC(PORT) (RS 232) (DF port)

Baud Rate- 9.6 Kbps to 19.2 Kbps

Driver softwares- RS Linx Classic, RS 232 & DF Drivers

Programming software- RS Logix 500

COMPUTERPLCDOWNLOADUPLOAD WORKING

Source mode: +ve supply is given to the PLC.Sink mode: -ve supply is given to the PLC.

The sink and source modes mainly define the way in which the I/O is connected to the I/O of the PLC.

PROGRAMMING the PLCProgramming language used: LADDER language( ladder 2). The programming can be done with simple contacts that simulate the opening and closing of relays, counters, timers, shift registers and other math operations.

Basic symbols:Input symbols: XIC- XIO-

Output symbols: OTE- OTL-

OUL-

ADDRESSING FORMAT : Identifier: slot address(if any).word address/bit

DATA FILES: micrologix 1000 contain the status information associated with the external I/O and all other instructions we use in our main and subroutine ladder program files.These files are organized by the type of data they contain. Data file types are:

PLC TIMER/COUNTER FUNCTION

TIMER ON(Ton)

COUNTER UP

MATH INSTRUCTIONS

Applications Material HandlingPackaging ApplicationsGeneral Industrial MachineryPrintingFood and BeveragePharmaceuticalWater Wastewater / SCADAClutch/Brake controlPosition Control - Pick-and-place / Conveyor

SCADASupervisory Control And Data AcquisitionIt is a software through which we can create visualization of any industrial process.Earlier, PLCs were programmed, download the program in it and it used to run for yearsThe problem- no one knew whats happening inside the PLC.Solution= PLC+SCADA

Supervisory Control and Data Acquisition

Supervisory means Monitoringentire system throughGUI representationof working Status ,of the entire systemControl means Controlling the entire System such as ON/OFF operation ,Speed controlling, temperature ControllingData Acquisitionmean collectingdata Information from Different controller, Sensor , Drives , Motor which are connected at distance through wire , Ethernet , wirelessUSEFULNESS OF SCADAProduction Division Quality DivisionMaintenance DivisionEngineering DivisionManufacturing Division

quality DIVISIONReal time production status Production schedulesProduction Information mgt.

PRODUCTION DIVISIONData integrity and quality controlIt is an open platform for statistical analysis

MAINTENANCE DIVISIONImproved troubleshooting and de-buggingPlant can be viewed remotelyCo-ordination between maintenance & mgmt. reduces unscheduled downtime.

MANUFACTURING DEPTT.Makes operation easier and repeatable with its real time functionality.Secured real time operation are maintained with windows.

TAGsIt is the address of the memory location where signals are being saved.We define a TAG in order to use it in the SCADA software (Intouch wonderware).TYPES : 1) Analog 2) Digital 3) Strings These are further associated with either Memory or I/O type tags.PC-SCADA Memory analog/digital/string tagPLC-SCADA - I/O analog/digital/string tag

DYNAMIC PROCESS GRAPHIC

FEATURES OF SCADADynamic Process GraphicTrends AlarmsSecurityDevice ConnectivityRecipe ManagementDatabase ConnectivityScript for logic development

TYPES OF SCADA PACKAGESD + R + N With this package development & editing of the application is possible runtime monitoring & control of the plant is possible & networking is possible.R + N With this package development & editing of the application is not possible , runtime monitoring & control of the plant is possible & networking is possible.Factory Focus - With this package developments & editing of the application is not possible . Runtime monitoring is possible but not control of the plant is possible. This package is used as a view node

SCADA SoftwareWonderware- IntouchRockwell- RS view32Siemens- winCCGE- Intellation

PLC-SCADA COMMUNICATION

PLC PROJECT(SILO SIMULATION)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.

SCADA PROJECT(AUTOMATIC BOTTLE FILLING PLANT)The project SCADA CONTROLLING AUTOMATIC BOTTLE FILLING PLANT has a motive to automate the filling of the liquid bottle from the tanks with the help of controlling through scada software.In this plant there are following major operations to be performed.The first one is designing the whole plant as it is in the field.secondly filling of the bottle to the required level with the help of 2 tanks and then transferring the contents of bottle to another bottle in different conveyor and transporting it .For different slider values the operation is performed.The bottle coming through conveyor is filled up by 2 tanks containing liquids of different colour and filling the bottle upto 50%.In the end when container becomes full it will transfer its material to another empty container on a different conveyor.

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