Training report 2012 2015-sonu yadav

INDUSTRIAL TRAINING REPORT


ON

“INDUSTRIAL AUTOMATION”

Submitted in partial fulfillment of the

Requirements for the award of the degree of

BACHELOR OF TECHNOLOGY

IN

Electronics’ & Communication Engineering.

(Session 2012-2015)

Submitted By:

Sonu Yadav

Roll. No: 2557005

Under the Guidance of

Mr. Sandeep

(H.O.D E.C.E)

Department of Electronics’ & Communication Engineering YADUVANSHI COLLEGE OF ENGINEERING & TECHNOLOGY

Narnaul Rewari Road, Patikra, Narnaul-123001(Haryana)


DECLARATION

I hereby declare that the Industrial Training Report done at “Digilog Automation Pvt. Ltd.” is

an authentic record of my own work as requirements of 6-months Industrial Training during the

period from January 2015 to July 2015 for the award of degree of B.Tech. (Electronics &

Communication Engineering), Yaduvanshi College of Engineering & Technology, Narnaul,

Mahendergarh, under the guidance of Mr. Sandeep (H.O.D E.C.E Dep’t)

Sonu Yadav

2557005

Date: ____________________

Certified that the above statement made by the student is correct to the best of our knowledge and belief.

Signatures

Examined by:

1. 2.

3. 4.

Head of Department (Signature and Seal)


CERTIFICATE

This training report is a genuine works by Mr. Sonu Yadav, B.Tech final yr, from Yaduvanshi

College of Engineering & Technology. The report was made under my supervision, and I express

my delight on it Successful completion. I also very happy to have offered her guidance whenever it

was required.

I wish her successful in all her future endeavors.

Mr. Sandeep Kumar Sonu Yadav

(H.O.D E.C.E Dep’t.) 2557005

E.C.E (8th

SEM)


ACKNOWLEDGMENT

I am thankful to the “Digilog Automation Pvt. Ltd” for providing

necessary facility to carry out my training successfully. I’d also like to

thank Er. Arun sing(M.E) and Er. Sunil Kumar (E.E), for enduring support

and guidance throughout the training I am very grateful to the whole

control and instrumentation Department for their support and guidance.

Also, I am highly obliged to the head of our training and placement cell

that provided me such a great opportunity to do my summer training in a

reputed institute like.

Digilog Automation Pvt. Ltd

ISO 9001-2008 Certified Company…

Sonu Yadav

2557005

E.C.E 8th

Sem.


PREFACE

It gives me an immense pleasure to submit this report as a part of practical training of 6 Months

Practical training is the most important part of the engineering studies.

During the course of the training a trainee learns to correlate both the practical problem to the

possible theoretical knowledge or solution .This training record is prepared on the basis of my

own experience gained during my practical training. On the basis of information collected and

guidance provide I had prepared a comprehensive training report. This report contain the history,

Introduction, quality policy and description op PLC, SCADA, HMI, instrumentations

Sonu Yadav

E.C.E 8th Sem.

2557005


Table of Content

S.No Particulars Page No. 1. Abbreviation 7

2. Training Establishment Page

3. Automation

Introduction 8

Example of automation 8 to 9

Types of automation, industrial automation 10-15

4. Programmable logic controller PLC

Introduction, Relay 16

History of PLC, Advantages 17 to 19

Inside PLC, CPU, RAM, ROM, EEPROM, I/P Module 20 to 21

Output Module. Sensor, Actuator 22 to 24

Number system, decimal, binary 25 to 26

Converting binary to decimal, Bits, byte words.logic1, logic0 27 to 29

BCD, Hexadecimal, communication 31 to 32

PLC operation, Programming PLC, Ladder logic, Example 33-37

5. SCADA 38-44

Introduction 38

System concept 39

Tags, types of Tags, classification of tags 40 to 41

Alarm, System components, Salient features 42 to 43

Benefits SCADA/HMI, Recommend 44

6. HMI

Introduction, types, difference between 45 to 47

7. Instrumentation, Application of automation, plc SCADA 48 to 49

8. Conclusion 50

9. References 51

10. Bibliography 52


General Abbreviation

PLC: Programmable logic controllers.

SCADA: Supervisory control and data acquisition.

I/P: Input

O/P: Output.

T-On: On timer.

T-Off: Off timer.

M: Memory Bits.

Q: Output in program.

MW: Memory words.

NO: Normally open.

NC: Normally closed.

DCS: Distributed Control System.

HMI: Human machine interference.

VFD: Variable Frequency Drive.

MD: Memory Double Word.

MB: Memory Byte

XIC: Examine If Closed

XIO: Examine If Open


TRAINING ESTABLISHMENT

Digilog Automation Pvt. Ltd.

Digilog Automation Pvt Ltd., , a part of Digilog Group, has been an integral part of the industrial

automation fraternity since 1989. The company is engaged in providing Sales and Services for

reputed manufacturers of automation products and its range of industrial products.

Digilog Automation Pvt Ltd offers automation consultancy for an entire spectrum of machinery

and industrial processes, fulfilling the growing expectations of customers. The sequence of

operations at the company includes a detailed study of customers’ applications, developing

comprehensive solutions followed by the proper commissioning of the automation systems.

Our success can be attributed to the incorporation of the innovative technologies in our

functioning. This includes being abreast with the latest advancement in PLC, PC, VFD, Servo

drives based motion control systems, SCADA systems and custom built PC software as applicable

to factory automation needs.

We have successfully completed more than 3000 projects for different customers.

Services offered:

Programmable Logic Controllers ( PLC)

Variable Frequency Drives ( VFD)

Servo Drives

Operator Terminals ( HMI)

SCADA projects


Control/Operator Panels

Motion Control Systems

Control and Power Panels

Industrial Computers

Training Programs.

Electronics for Robotics and Multi-axis controllers

Electrical Outsourcing and Reconditioning

Energy Conservation Projects.

Digilog team

With Digilog Automation Pvt. Ltd., , you benefit from a team of proven expertise in factory

automation solutions. Our engineers have successfully implemented machine control systems

converting brilliant design ideas into feasible realities for customers. Our programmers , specially

trained in new technologies have completed projects in diverse automation using products as

mentioned above.

Combine these quality of human resources with state-of the art infrastructure for a compete picture

of Digilog Automation Pvt. Ltd . Standing on this edifice, the company is poised to scale greater

heights of quality and innovation in its endeavor for customer satisfaction.

Over a period of several years Digilog has successfully commissioned and maintained over 300

systems in the region. This speaks about or promises and commitment to offer round the clock

service to each of our customers.

Application and Customer Domain

Pharmaceuticals


Machine Tools

Material Handling

Packaging

Plastics

Vaccum

Process Control.

Rubber

Utility

Welding

Plastics , Pipes moulding

Automatic Test Equipments

Chemicals.,

Conveyors

Esteemed Clients

Motor Industries Co Ltd.,

Perfect Circle India Ltd.,

Gabriel India Ltd.,

Mahindra and Mahindra Igatpuri

Mahindra and Mahindra Nagpur

Bosch Chasis., Jalgaon

Supreme Plastics Ltd , Jalgaon

Precise Vaccum Pvt Lt.d,

Atlas Copco Ltd.,

Chemito Industries Ltd.,

Orbital Systems Ltd.,


Graphite Vicarb India Ltd.,

Kiroskar Oil Engines Ltd.,

Veeraja Industries.

Contact Address

Digilog Automation Pvt. Ltd.,

4- A, Priyanka Pride .,

Near Water Tank., Mahatmanagar.,

Nashik 422007

Phone :+91-253- 6610070

Mail : [email protected]

Web : www.digilog.co.in

mailto:[email protected]

http://www.digilog.co.in/


Chapter: 1

AUTOMATION

Introduction

Automation is the use of control system such as computers to control industrial machinery &

process, reducing for need for human intervention. In the scope of industrialization,

Automation is a step beyond mechanization. Whereas mechanization provided human operators

with machinery assist them with physical requirement of work, automation greatly reduces the

need for human sensory and mental requirements as well. Process and system can also be

automated.

In other words

Automation is a delegation of human control function to technical equipment for increasing productivity, to

better quality, to reduce cost & increase in safety working condition, to reduce manpower.

Example of automation

a) Automatic machine tools to process parts- CNC m/c

b) Industrial robots

c) Automatic material handling

d) Feedback control system


EXAMPLE OF AUTOMATION

Automatic Material Handling Conveyors.

Industrial Robots


feedback control systems

TYPES OF AUTOMATION

1) Fixed automaton

2) Programmable automation

3) Flexible automation

Fixed automation

Fixed automation refers to the use of custom-engineered (special purpose) equipment to

automate a fixed sequence of processing or assembly operations. This is also called hard

automation.

The primary drawbacks are the large initial investment in requirement and the relative

flexibility.


Programmable automation

In programmable automation, the equipment is designed to accommodate a specific class of

product changes and the processing or assembly operation can be changed by modifying the

control program.

Flexible automation

In flexible automation, the equipment is designed to manufacture a variety of products or

parts and very little time is spend on changing from one product to another . A flexible

manufactures various combinations of products according to any specified schedule.

INDUSTRIAL AUTOMATION

Field instrument

This type of instrument mainly used to get the feedback any type of process carried our so

they mainly use:

1. Sensors,

2. Transducer and

3. Transmitter

PLANT

Monitoring &

controller Field

instrument Intelligent

controller


Proximity Sensor.

Intelligent controller

This device is basically micro control based or micro controller device mainly intelligent

controllers are:

i. Programmable logic controller (PLC)

ii. PID Controller

iii. Distributed controller system (DCS)

iv. Computer Numerical controller (CNC


PLC

PID


CNC MACHINE

Monitoring and controller

This type of device to control whole plant just in a setting in control room, so mainly control

device are

Supervisory Control & Data Acquisition (SCADA)

Human Machine interface (HMI)


600 Series touch screen HMI.


Chapter: 2

PROGRAMMABLE LOGIC CONROLLER

Introduction

A PLC is a solid device designed to perform the function previously accomplished by

components such as electromechanical relay, drums switch, mechanical timers /counter etc.

for the control and operation of manufacturing process equipment and machinery. Even

thought the electromechanical relay (control relay, pneumatic timer relay, etc) have served

well for many generations, often under adverse conditions, the

ever increasing sophistication and complexity of modern processing equipment requires

faster acting, more reliable functions that electromechanical relays or timing devices can’t

offer.

What is relay?

A relay is an electromechanical switch, operated by passing current through a coil wire wound

around a steel core, which act as an electromagnet pulling the switch contact down or break a

circuit

Figure:Relay

HISTORY OF PLC

The first programmable logic controller were designed and developed by Modicon as

a relay replacer for GM and Landis.


This controller eliminated the need for rewiring and adding additional for each new

configuration of logics.

The new system drastically increased the functionality of the control while reducing

the cabinet space that housed the logic.

The first PLC, model 084, was invented by Dick Morley in 1969.

The first commercial successful PLC, the 184, was introduced in 1973 and was

designed Michael Greenberg.

ADVANTAGES

PLC not only capable of performing the same tasks as hard-wired control, but are also capable of many

more flexible application. In addition, the PLC program and electronic communication lines replace much

of the interconnecting wires require hardwire control. Therefore, hard wiring, thought still required to

connect field device, is less intensive. This also makes correcting errors and modified the application

easier.

Some of the additional advantages of PLCs are as follow

Smaller physical size than hard-wire solutions

Easier and faster and to make changes.

PLCs have integrated diagnostics and override functions

Diagnostics are centrally available


Application can be immediately documented

Application can be duplicated faster and less expansively

Speed in operation

Security

Online/ offline modifications

P ho t o gr aph s ho wi ng s ev e ra l i np u t an d o u tp u t mo du l es o f a s i n gl e

A l l e n - Bradley PLC.

INSIDE PLC

The Central processing Unit (CPU), contains and internal program that tells the PLCs how to

perform the following functions:

Execute the control instructions contained in the user’s Programs. This program is store in

“nonvolatile” memory,

Meaning that the program will not be lost if power is removed.

Communicate with other device, which can include I/O Device, programming device,

networks and even other PLCs

Performs housekeeping activities such as communication, internal diagnostic, etc.


THE CPU

The microprocessor or processor module is the brain of PLC system. It consists of the

microprocessors, memory integrate circuits, and circuits necessary to store and retrieve

information from memory. It also includes communication ports to the other peripherals, other

PLCs or programming terminals. Today’s processors vary widely in their capabilities to control the

real world devices. Some control as few as 6 inputs and outputs (I/O) and other 40,000 or more.

One processor can be control more than one process or manufacturing line. Processors are often

linked together in order to provide continuity throughout the process.

RAM

RAM or Random Access Memory is a volatile memory that would lose its information if power were

removed. This is why some processors units incorporate a battery back-up. This type of RAM normally

used CMOS or Complementary Metal Oxide Semiconductor. CMOS RAM is used for storage of the user’s

program (ladder logic diagrams) and storage memory.


ROM

ROM or Read only memory is a non volatile memory. This means you don’t need external power source to

keep information. In this type of memory, information can be read, but not changed. For these reason the

manufacture sometimes calls this firmware. It is placed their for the internal use and operation of

processors units.

EEPROM

EEPROM or Electrically Erasable programmable Read Only Memory is usually an add-on

memory module that is used to back of the main program in COSMOS RAM of the processors.

Can be programmed to load the EEPROM’s program to RAM is lost or corrected.

INPUT MODULE

There are many types of input module to choose form. These type of module used is dependent

upon what real world input to the PLCs is desired. Some example input is limit switches, electric

eyes, and pushbuttons. DC input, such as thumbwheels switches, can be used to enter integer

values to the manipulated by the PLC, DC input cards are used for this application. Since most

industrial power systems are inherently noisy, electrical isolation is provided between the input and

the processor. Electromechanical interference (EMI) and radio frequency interference (RF) can be

cause severe problems in most solid state control systems. The component used most often to

provide electrical isolation within I/O cards is called an optical isolator. The wiring of an input is

not complex. The object is to get a voltage at a particular point on the card. Typically there are 8 to

32 input points on any one input module. Each point will be assigned a unique address by the

processor. Analog input modules are special cards that use analog to digital conversion (A to D) to

sense variables such as temperature, speed, pressure and position. The external device normally is


connect to a controller (transducer) producing an electrical signal the analog input card can

interpret. This signal is usually 4 to 20 Ma or 0 to 10 volts.

OUTPUT MODULE

Output modules can be used for ac or dc devices such as solenoids, relay, contractor, pilot lamps,

and LED readouts. Output card usually have from 6 to 32 outputs on a signal module. The output

device within the cards provides the connection from the user power supply to the load. Usually

silicon controlled rectifier (SCR), triac, or dry contact relay are use for this purpose. Individual


output are rated most often at 2 to 3 amperes. Output cards, like input cards have electrical

isolation between the load being connected and the PLC. Analog output cards are a special type

of output modules that use digital to analog conversion (D to A). The analog output module can

be take a value store in a 12 bit file and convert it to an analog signal. Normally this signal is 0-10

volts dc or 4 to 20 Ma. This analog signal is often used in equipment such as motor operated

valves and pneumatic position control device.

SENSORS

A sensor is a device that converts a physical condition into an electrical signal for use by the PLC. Sensors

are connected are input of a PLC. A pushbutton is one example of sensors that is connected to the PLC input.

An electrical signal is sent from the pushbutton to the PLC indicating the condition (open/closed) of the push

button contacts.

Pushbutton (Sensors)

ACTUATOR

Actuators convert an electrical signal from the PLCs into a physical condition. Actuators are connected to

the PLC output. A motor starter is one example of actuator that is connected to the PLC output. Depending

on the PLC signal the motor starter will either start or stop motor.

PLC INPUT

Actuator (Starter) Motor

PLC INPUT


NUMBER SYSTEM

Since PLCs is computer it stores information in the form of on or off conditions (1 to 0), refers to

as binary digits (bits). Sometimes binary digits are used individually and sometimes they are used

to represent numerical valves.

DECIMAL SYSTEM

Various number system are used by PLCs. All number systems have the same three characteristic:

Digits

Base

Weight.

The decimal system, which is commonly used in everyday life, has the following characteristic:

Ten digits 0,1,2,3,4,5,6,7,8,9

Base 10

Weights 1, 10, 100, 1000……

BINARY SYSTEM

The binary system is used by programmable controllers. The binary system has the following

characteristic:

Two digits 0,1

Base 2


Weights power of base 2 (1, 2, 4, 8, 1, 6……)

In the binary system 1s 0s are arranged into columns. Each column is weights. The first column

has a binary weight of 2.

This is equivalent to decimal 1. This is referred to as the least significant bit. The binary weight is

double with each succeeding column. The next column, for example, has a weight of 2^1which is

equivalent to decimal 2. The decimal value is double in each successive column. The number in

the far left hand column is referred to as the most significant bit. In this example, the most

significant bit has a binary weight of 2^7. This is equivalent to decimal to 128.

CONVERTING BINARY TO DECIMAL

The following steps can be used to interpret a decimal number from a binary value.

1. Search from least to most significant bit for 1s .

2. Write done the decimal representation of each column containing a 1.

3. Add the columns values.


In the following example, the fourth and fifth columns from the right containing a 1.The decimal

values of the fourth column from the right is 8, and the decimal value of the fifth column from the

right is 16. The decimal equivalent of this binary number is 24. The sum of all the weighted

columns that contains a 1is the decimal number that the PLC has stored

BITS, BYTES, AND WORDS

Each binary piece of data is a bit. Eight bits make of one byte.

Two bytes, or 16 bits, make of one word.


LOGIC 1, LOGIC 0

Programmable controllers can only understand a single that that is on or off (present or not

present).the binary system is a system in which there are only two numbers, 1 and 0.

Binary 1 indicates that a signal is present, or the switch is on.

Binary 0 indicates that a signal is present, or the switch is off.

BCD (Binary-coded decimal)

Binary-coded decimal (BCD) are the decimal number where the each digit is represented by a

four-bit binary number. BCD is commonly used with input and output devices. Thumbwheel stitch

is one example of an input device that uses BCD. The binary number is broken into group of four

bits, each group representing decimal equivalent. A four-digit thumb wheel switch, like the one

show here, would control 16 (4*4) PLC inputs.


22

HEXADECIMAL

Hexadecimal is another system used in PLCs. The hexadecimal has the following characteristic:

16 digits 0,1,2 ,3,4,5,6,7,8,9,A,B,C,D,E,F

Base 16, weights power of base 16(16, 256, 4096…..)

The ten digits of the decimal system are used for the first ten digits of the hexadecimal system. The

first six letter of the alphabet are used for the remaining six digits.

A=10, B=11, C=12, D=13, E=14, F=15

The hexadecimal system used in PLCs because it allows the statues of large number of binary bits

to the represented in a small space such as on a computer screen or programming device display.

Each hexadecimal digit represented the exact of the four binary bits. To convert a decimal number

to a hexadecimal number the decimal number is divided by the base of 16.


To convert decimal 28, for example, to hexadecimal

Decimal 28 divided by 16 is 1 with a remainder 12. Twelve is equivalent to C in hexadecimal. The

hexadecimal equivalent of decimal 28 is 1c.

The decimal value of a hexadecimal is obtained by multiplying the individual hexadecimal digits

by the base 16 weight and the adding the results. In the following example the hexadecimal

number 2B is converted to its decimal equivalent of 43.

23

COMUNICATION

There are several methods to communicate between a PLC and programmer or even between two

PLCs. Communications between a PLC and a programmer (PC or Hand held) are provided by the

makers and you only have to plug in a cable from your PC to the programming port on the PLC.

The communication can be RS232, RS485 or TTY. Communication between two PLCs can be

carried out by dedicated links supplied/ programmed by the makers (RS232 etc) or via outputs

from one PLC to the input on another PLC. The direct link method of communication can be as a


simple as, if an output on the PLC is on then the corresponding input on the second PLC will be on

and then this input is used within on the program on the second PLC

PLC OPERATION

There are four basic steps in the operation of all PLCs. Which continually take place in a repeating

loop.

Input scan

Program scan

Output scan

Housekeeping

Input Scan

Detect the state of all input device that are connect to the PLCs.


Program Scan

Execute the user create program logic.

OUTPUT SCAN

Energize or de-energize all output devices that are connect to the PLCs.

HOUSEKEEPING

This step includes communication with program terminals, internal diagnostic etc.

CHECK INPUT STATES

First the PLC takes a look at each input to determine if is on or off. In other words, is the sensors connected

to the first input on? Then second input? Then the third so on…it records this data into its memory to be

used during the next step.

EXECUTE PROGRAM

Next PLC executes your program one instruction at a time.

Maybe the program says that if the first input was on then it should on the first output. Since it is already

knows which input are on/off from the previous step it will be able to decide whether the first output should

be turn on based on state of first input. It will store the execution result for use during the next step.

UPDATE OUTPUT STATES

Finally the PLC updates the state of the outputs. It update the outputs base on which inputs were

on during the first step and the result of executing your program during the second step. Based on

the example of step 2 it would now turn on the first output because the first input was on and your

program said to turn on the first output when this condition is true.


After the third step the PLC goes back to step one and repeats the step continuously. One scan time

is defined as the time is takes to execute the 3 steps listed below.

PROGRAMMING PLC

Various languages are used for programming of PLCs.

Ladder Diagram ( LD)

Ladder diagram is a graphic programming language derived from the circuit diagram of directly

wired relay control. The ladder diagram contains contact rails to the left the right of the diagram,

these contact rails are connected to switching elements (normally open/ normally closed contacts)

via current path and the coil elements.

FUNCTION BLOCK DIAGRAM (FBD)


In the function block diagram, the function and blocks are represented graphically interconnected

into networks. The function block diagram originates from the logic diagram for the design of

electric circuits.

SEQUENTIAL FUNCTION CHART (SFC)

The sequential function chart is language resource for the structuring of sequence- oriented control

programs. The element of the sequential function charts are steps, transition, alternative and

parallel branching. Each step represents a processing state of a control program, which is active or

inactive. A step consists of action which identical to the transition, are formulated in the IEC 1131-

3 languages. Action themselves can again contain sequence structure. The feature permits the

hierarchical structure of the control program. The sequential Function Chart therefore an excellent

tool for the design and structuring of control programs.

LADDER LOGIC

Ladder Logic, Ladder programs is the most common programming language used to program a

PLC.


Ladder Logic was one of the first programming approaches used in PLCs because it borrowed

heavily from the relay diagram that plant electricians already knew.

The symbols used in relay ladder Logic consists of a power rail to the left, a second power rail to

the right. The logic of each circuit (or rung) is solved to the left to right. The symbols of these

diagram look like a ladder with two side rails and circuits that resemble rungs on ladder.

The picture above represented single “rung” of ladder

If input is on (or true)- power (logic) completes the circuits from the left rail- and output

turns ON(or true)

If output is off (or false)- then the circuit is not complete and logic does not follow to the

right- and output 1 is OFF

There are many logic symbols available in ladder logic-includes

Timers , counter , Math, and Data moves such that any logical condition or control loop can

be represented in ladder Logic. With just hand full of basics symbols – a normally open

contact, normally closed contact, normally open coli, normally close coils, timer, counter

most logical conditions can be represented.

CONTACT AND COILS With just the normally open contact and normal open coil a surprising array of basic logical conditions can

be represented.

Normally open contact This can be used to represent any input to the control logic- a switch or sensor, a contact from an output, or

an internal output.


When “solved” the reference input is examined for an ON (Logic1) condition. if it is ON, contact will

closed and allow power (logic) to flow from left to right. If the state is off (logic 0).then contact is open,

power (logic) will NOT from left to right.

Normally open coil

This can be used to represent any discrete output from the control logic

When “solve” if the logic to left of the coil is TRUE, the referenced OUT is ON (logic1)

SOLVING SINGLE RUNG

Suppose a switch is wired to input, and a light bulb is wired through output 1 in a such way that the

light is OFF when output1 is off and ON when output1is ON.

When input1 is OFF (logic 0) the contact remaining open and power can’t flow from left to right,

therefore,Output1 remain off (logic 0)

When input is ON (logic 1) then the contact close, power flows from left to right, and output1

becomes ON (the right turns ON)


THE AND RUNG

The AND is a basic fundamental logic condition that is easy to directly represent in Ladder Logic.

Suppose a switch is wired to Switch1, a second switch is wired toSwitch2, and a light bulb is wired

through Light1 in such a way that the light is OFF when Light1 is OFF, and ON when Light1 is

ON.

In order for Light1 to turn ON, Switch1 must be ON, AND Switch2 must be ON.

If Switch1 is OFF, power (logic) flow from the left rail, but stops at Switch1. Light1 will be OFF

regardless of the state of Switch2.

If Switch1 is ON, power makes it to Switch2. If Switch2 is OFF, power cannot flow any further to

the right, and Light1 is OFF.

If Switch1 is ON, AND Switch2 is ON - power flows to Light1 solving its state to ON.

THE OR RUNG

The OR is a logical that is easy to represent in ladder diagram


Suppose a switch is wired to switch 1, second switch is wired to switch 2, and the light bulb is wired through a light1 in

such a way the light is OFF when light is OFF, and ON when light is ON. In this instance, we want to the light to turn

ON if either switch1 OR switch is ON.

If switch1 is ON - power flow to Light1 turning it ON.

If switch2 turn is ON – power flows through the switch2 contact, and up the rail to light1- turning it ON.

If switch1 AND Switch2 are ON- light1 is ON.

The only way Light1 is OFF is if Switch1 AND Switch2 are OFF.

MOTOR STARTER EXAMPLE:


First consider a hardwired approach

The following line diagram illustrate how a normally open and a normally closed pushbutton might be connected to

control a three -phase AC motor as shown above figure.

In this example , a motor starter coil (M) is wired in series with a normally open, momentary start pushbutton, a

normally closed , momentary stop pushbutton , and normally closed overload relay (OL) contacts.

Momentarily pressing the start push button complete the path for current flow and energies the motor starter (M). This

close the associated M and Ma (auxiliary contact located in the motor starter ) contacts. When the start button is released,

current

Continues to flow through the stop button and the Ma contacts, and the M coil remains energized. The motor will run

until the normally closed stop button is pressed, unless the overload relay (OL) contacts open . when the stop button is

pressed, the path for current is interrupt , opening the associated M and Ma contacts and the motor stop.


Chapter 3

SCADA

Introduction

SCADA is not a specific technology, but a type of application

“SCADA” stands for Supervisory Control And Data Acquisition –any application can gets data

about a system in order to control the system is a SCADA application’’ it is a purely software

package that is positioned on top of hardware to which it is interfaced , in general via Programmable

logic controller (PLCs), or other commercial hardware modules.

In other words

SCADA: the term refers to a large scale, distributed measurement (and control) system. SCADA are

used to monitor or to control chemical, physical or transport process.

SCADA it is refers to an industrial control system a computer system monitoring and controlling

process. The process can be industrial, infrastructure or facility describe below

Industrial process: it is includes those of manufacturing, production, power generation,

fabrication, and refining and process may be in continuous, batch, repetitive or discrete or

modules.

Infrastructure process: it may be public or private and water treatment and distribution,

wastewater collection, and treatment, oil and gas pipelines , electric power transmission and

distribution, and large communication systems.


Facility Process: it is occur both in public facilities and private ones, including building, airports,

ship and space station. The monitor and control HVAC, access and energy consumption

A SCADA system usually consists of following subsystem

A Human – Machine interface (HMI) is the apparatus which present process data to

human operator, and through this, the human operator monitor and control the process.

A supervisory (computer) system, gathering (acquiring) data on the process and sending

commands.

Remote terminal unit (RTU) connection to sensors in the process and converting sensors

signals to digital data and sending digital data to the supervisory system.

Programmable Logic Controller (PLC) used as field devices because they are more

economical, versatile, flexible configurable than special purpose -RTUs.

Communication infrastructure connection the supervisory system to the Remote Terminal

Unit.

Systems Concepts

The terms SCADA usually refer to a central system that monitors and controls a complete site. The bulk of

the site control is actually performed automatically by a Remote Terminal Unit (RTU) or by a

programmable Logic controller (PLC). Host control functions are almost always restricted to basic site

override or supervisory level capability.

EX: A PLC may control the flow of cooling water through part of an industrial process, but the SCADA

system may allow operators to change the set points for the flow, and enable alarm condition, such as loss

of flow and high temperature, to be displayed and recorded. The feedback control loop passes through the

RTU or PLC while the SCADA system monitors the overall performs of the loop.


TAGS (POINTS)

It is logical name of a variable or object that be used in our animation of a plant.

Tags are two types

System defined Tags

User defined tags

System defined tags

It is represent the system value in the SCADA it is represented by dollar sing $


User defined tags

This tag are defined by the user or programmer

Except (A,S) are not defined.

Trends:

it is used for graphical representation of process

Two types

Real times trends

Historical Times trends

Classification of tags

Direct tags

Indirect tags

Direct tags

These tags are directly used by the programmer to represent the value of plant or variable

Indirect tags

These tags are used by the another tags to show or represent the value of plant or variable

Direct tags

Memory tags: these tags having no connection with process the plant.


ALARM

An important part of most SCADA implementation is alarm handling. The system monitors whether certain

alarm conditions are satisfied, to determine when an alarm event has occurred. Once alarm event has

been detected, one or more action are taken (such as the activation or remote SCADA operators are

informed) in many case, a SCADA operate may have to knowledge the alarm event, these may be

deactivate some alarm indicators whereas other indicators remain active until the alarm conditions are

cleared. Alarm conditions can be explicit - for example, an alarm point is a digital status point that has

either the value NORMAL or ALARM that is calculated by a formula based on the values in other analogue

and digital points- or implicit: the SCADA system might automatically monitor whether the value in an

analogue point lies outside high and low limit values associated with that point. Examples of alarm

indicators include a siren, a pop-up box on a screen, or a colored or flashing area on a screen (that might

act in a similar way to the "fuel tank empty" light in a car); in each case, the role of the alarm indicator is to

draw the operator's attention to the part of the system 'in alarm' so that appropriate action can be taken.

In designing SCADA systems, care is needed in coping with a cascade of alarm events occurring in a short

time, otherwise the under lying cause (which might not be the earliest event detected) may get lost in the

noise. Unfortunately, when used as a noun, the word 'alarm' is used

rather loosely in the industry; thus, depending on context it might mean an alarm point, an alarm

indicator, or an alarm event.

SYSTEM COMPONENTS

The three components of a SCADA system are:

1. Multiple Remote Terminal Units (Also knows as RTUs or outstation)

2. Central control Room with host computer (s)

3. Communication infrastructure


Remote Terminal Unit (RTU)

The RTU connects to physical equipment and read status dada such as the open/close status from a switch

or a valve, read measurements such as pressure, flow, voltage or a valve, or setting the speed of a pump.

The RTU can read digital status data or analogue measurement dada, and send out digital commands or

analogue.

Salient feature of modern SCADA system

1. User- friendly (X-windows/graphic) interface.

2. Automatic control.

3. Off-line processing.

4. Integrated environments.

5. Extensive Historical data manipulation.

6. Extremely high data throughput

7. On-line complex electrical network analysis.

8. Real time supply/ demand- side economic calculations.

9. Automatic voltages and power factor correction.

10. Distributed processing power.

Benefits HMI/SCADA

1. Powerful monitoring and control over your production

2. Ease of use for New and experienced users.

3. Robust connectivity to other software, system and devices

4. True client /server Architecture for ease Scale ability

5. Powerful thin client technology.

6. Sophisticate Alarm and trending.


SCADA Recommended

1. LAN /WAN support

2. Import from multiple PLC system

3. Support for low bandwidth operation.

4. Secure & flexible.

5. Low CPU & memory requirements.

6. Drives work on Rs232, 422, 485, TCP/IP.

7. Unlimited number of tags (tags support 80 char).

8. Graphic (transparent color support, advanced animation without coding, import graphic

window bitmap –Auto Cad, fax image.

9. Supervision

10. Controlling

11. Dada collection

12. Interface of PLCs

13. Alarm.


Chapter 4

Human Machine Interface (HMI)

Introduction

HMI is the smallest form of SCADA which is used for monitoring and controlling and it is

combination of hardware and software.

Human machine Interface:

The HMI/SCADA industry was essentially out of a need for user friendly front-end to a control

system containing programmable logic controller (PLC). While a PLC does provide automated,

preprogrammed control over a process, they are usually distributed across a plant, making a difficult

to gather data from them manually. additionally, the PLC information are usually in crude user-

unfriendly format. The HMI/SCADA gather information from the PLCs via some form of

communication method, and combines and formats the information. Since the early1990s the role of

SCADA system in large civil engineering solutions has changed, requiring them to perform more

operations automatically. A sophisticated HMI may also be linked to a database to provide instant

trending diagnostic data, scheduled maintenance procedures, logistic information, detail schematics

for a particular sensors or machine, expert –system troubleshooting guides.

Since about 1998 , virtually all major PLC manufacture have offered integrated HMI/SCADA

system, many of them using open and non proprietary communication protocols.

Types of HMI

1. Keypad

2. Touch screen

3. Keypad + touch scree


Difference between SCADA and HMI

SCADA

It is software

It is work at low temperature

Screen ratio of SCADA is large

Local and Remote control

Data base connectivity is possible

Range of SCADA

HMI

it is combination of s /w and h/w

it is work at high temperature & low

Screen ratio of HMI is Low i.e 6 inch

LAN area Control

Data base connectivity is not possible

Range of HMI is 100m

Instrumentation

Instrumentation is a branch of engineering electric (science) which is used for measurement of

process parameters and electric parameters it include, flow meter, thermocouple, level instrument

etc.

Transducer:

It is device which converted one form of engineering into another form of energy.

Sensors:

It is transducer which converted one form of energy into measurable form of energy.


Types of sensors

1. Flow meter

2. Pressure sensors

3. Ambient meter

Transmitter It is a device which is used for the transmission of signal over long distance so generally used for transmitter.


Chapter 5

Application for PLC in substation automation & SCADA

Electric power generation, transmission and Distribution.

Manufacturing industries.

Mass transit & whether management system

Traffic signals.

Cement and petrochemicals industries.

Automobiles industries


There are many applications for PLC for substation automation, distribution automation &

SCADA system. As utility engineers become more familiar with capability of PLCs and PLC

manufactures develop a new substation specific products. The number and type of potential

applications continues to increase.

RTU (Remote terminal Unit) emulation & replacement

Alarm reduction & intelligent messaging

Utilize existing SCADA protocols

Ethernet, TCP/IP

Multiprotocol, DNP 3.0, Modbus plus

Analog & Discrete I/O

Protection & control

Protective relay interface/ intrection

Automatic switching

Automatic transfer schemes

Circuit breaker control &interlocking

Feeder automation & fault recovery

Automatic service restoration

Emergency load Shedding

Station HMI- Graphic user interface (GUI)

Remote control

Demand control


CONCLUSION

This report has discussed the role that programmable logic controller have in efficient design and control

of mechanical process. Also discussed was the understanding,

AUTOMATION, SCADA, HMI, Instrumentation and the programming involved with

it. Finally, the report has discussed as complete Automation, like a , relay,

Components, history.

Programmable Logic Controller, history, advantages. Inside PLC etc…

PLC components, understanding Ladder logic, example

SCADA: this section contains basic introduction of SCADA, features,

Recommended, Tags, Trends

Difference between SCADA & HMI.

HMI: This section contains basic HMI, types of HMI, introduction.


REFERENCE

1. Pollet, Jonathan, SCADA Security Strategy, Plant data Technology, August 8, 2002

2. www.scadanews.com

3. www.princeton-indiana.com/wasetewater/Pages

4. www.ref.web.cern.ch/ref/CERN

5. www.sss-mag.com/scada.html

6. www.scada.com

7. www.scrib.com


BIBLIOGRAPHY

1. Study material by Prolific automation system pvt. Ltd.

2. Study material by Futronix automation pvt. ltd.

3. Programmable logic by John. R . Hockwarth

4. Controllers Programmable logic by L.N.Bryan

5. Controllers E.A.Bryan

6. Programmable logic by W.Batton

7. Controllers Automatic manufacturing by Hugh Jack

8. System with PLC Communication technology guidelines for SCADA system, power

delivery by Marihart, D.J

Training report 2012 2015-sonu yadav

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