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JAIPUR, RAJASTHAN
A
TRAINING REPORT ON
PLC SCADA AND AUTOMATION
2015-16
SUBMITTED TO
MR. S N JHANWAR
SUBMITTED BY
VIKASH RANJAN
1 Acknowledgement 3
2 Company profile 4
3 Introduction to automation 6
4 Advantage/Disadvantage 8
5 Limitation of automation 9
6 PLC 10
7 Architecture of PLC 12
8 Ladder Diagram 14
11 Application of PLC 30
12 SCADA 31
13 SCADA Software 33
14 Architecture 34
16 Application of SCADA 44
17 Conclusion 47
2
ACKNOWLEDGEMENT
First & foremost I extend my thanks & gratitude to the entire unit
of “KAIZEN ROBEONICS PVT.LTD. JAIPUR” along with “Mr.
Manoj Sharma (DIRECTOR)”,“SMr. Amit Kumar (Assistant
Professor)” whose guidance, teaching and invaluable suggestions
provided me a deep insight in my chosen field of technology,
enhanced my knowledge and supported in widening my outlook
towards the communication industry. I am also very thankful to
all the engineers of the department for their kind support
throughout the training.
3
COMPANY PROFILE
Kaizen is a Japanese term for improvement. More than a word it is
the philosophy that focuses upon the continuous improvement in
any process. It can be applied to any field in the world – from self
improvement to business processes and from scientific research
to education. Kaizen aims at improving the activities and process
thus eliminating waste.
4
Research Pvt. Ltd. accomplish this task by providing education in
Robeonics and carrying out research and development activities in
the field for the overall development of science and technology.
Kaizen Robeonics Research Pvt. Ltd. is also aimed to continuously
improve its processes in education and research.
5
INTRODUCTION TO AUTOMATION
Automation Impacts:
Advantages of Automation:
Disadvantages of Automation:
1. Technology limits: Current technology is unable to automate all
the desired tasks.
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2. Unpredictable development costs: The research and
development cost of automating a process may exceed the cost
saved by the automation itself.
3. High initial cost: The automation of a new product or plant
requires a huge initial investment in comparison with the unit
cost of the product.
Applications
Automated manufacturing:
Automated manufacturing refers to the application of
automation to produce things in the factory way. Most of the
advantages of the automation technology has its influence in
the manufacture processes.
The main advantages of automated manufacturing are
higher consistency and quality, reduced lead times,
simplified production, reduced handling, improved work
flow, and increased worker morale when a good
implementation of the automation is made.
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Home automation:
Home automation designates an emerging practice of
increased automation of household appliances and
features in residential dwellings, particularly through
electronic means that allow for things impracticable, overly
expensive or simply not possible recent past decades.
Industrial automation:
Industrial automation deals with the optimization of energy-
efficient drive systems by precise measurement and control
technologies. Nowadays energy efficiency in industrial
processes are becoming more and more relevant.
Semiconductor companies like Infineon Technologies are
offering 8-bit microcontroller applications for example
found in motor controls, general purpose pumps, fans, and e-
bikes to reduce energy consumption and thus increase
efficiency.
Limitations to automation:
Current technology is unable to automate all the desired tasks.
8
PROGRAMMABLE LOGIC CONTROLLER
HISTORY OF PLC:
9
which a PLC could be programmed (block diagrams, instruction
list, C, etc.).
INTRODUCTION OF PLC:
10
In simple words, Programmable Logic Controllers are relay
control systems put in a very small package. This means that one
PLC acts basically like a bunch of relays, counters, timers, places
for data storage, and a few various other things, all in one small
package.
ARCHITECTURE OF PLC:
The PLC give output in order to switch things on or off. The PLC’s
output is proportionally activated according on the status of the
system’s feedback sensors and input terminal which is connected
to PLC. The decision to activate output are based on logic
programmes. The logic programme stored in RAM or ROM
memory. The PLC also have same as computer, a CPU, data bus
and address bus
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to communicate with external devices such as programmers,
display monitor The next diagram shows a simplified diagram of
PLC’s structure. The central processing unit control everything
according to a programme stored in a memory (RAM/ROM
).Everything is interconnected by two buses ,the address bus and
data bus . The system must be able and a/d converter.
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Fig : Basic plc sections
13
Fig : ladder diagram
INPUT represented by I
OUTPUT represented by O.
Addressing method:
1 slot=32 bit=2 word (1 char./word=2 byte=16 bit)
Input addressing:
File letter:Slot number.Word number/Bit number
For example I:2.1/1
Output addressing:
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File letter:Slot number.Word number/Bit number
For example O:2.1/1
Input Instruction:
1. --[ ]-- This Instruction is Called XIC or Examine If Closed.
ie; If a NO switch is actuated then only this instruction will be
true. If a NC switch is actuated then this instruction will not be
true and hence output will not be generated.
2. --[\]-- This Instruction is Called XIO or Examine If Open
ie; If a NC switch is actuated then only this instruction will be
true. If a NC switch is actuated then this instruction will not be
true and hence output will not be generated.
Output Instruction:
1. --( )-- This Instruction Shows the States of Output(called
OTE).
ie; If any instruction either XIO or XIC is true then output will
be high. Due to high output a 24 volt signal is generated from
PLC processor.
2. --(L)-- Output Latch (OTL)
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OTL turns a bit on when the rung is executed, and this bit
retains its state when the rung is not executed or a power cycle
occurs.
3. --(U)-- Output Unlatch(OTU)
OTU turns a bit off when the rung is executed, and this bit
retains its state when the rung is not executed or when power
cycle occurs.
Rung:
Rung is a simple line on which instruction are placed and logics
are created
E.g.; ---------------------------------------------
Timer:
Timer has three bit:
EN: Enable bit :
The Timer Enable (EN) bit is set immediately when the rung
goes true. It stays set until the rung goes false.
TT: Timer timing bit :
The Timer Timing (TT) bit is set when the rung goes true. It
stays set until the rung goes false or the Timer Done (DN) bit is
set (i.e. when accumulated value equals preset value).
DN: Done bit:
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The Timer Done (DN) bit is not set until the accumulated value
is equal to the preset value. It stays set until the rung goes false.
Timer is three type:
1. TON 2. TOF 3. RTO
1. TON: Timer On
Counts time base intervals when the instruction is true.
Fig : Timer on
2. TOF: Timer off
Delay Counts time base intervals when the instruction is false.
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Fig : Retentive Timer
Addressing of timer:
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Set When Accumulated value wraps around to +32,768 (from: 32
767) and
Counter:
Counter has three bit:
Count Up bit (CU):
Set When Rung conditions are true and remains set till rung
conditions go false or a RES instruction that has the same
address as the CTD instruction is enabled.
Done bit ( DN):
Set when the accumulated value is => the present value and
remains set till the accumulated value becomes less than the
present value.
Overflow ( OV):
continues counting from there and remains set till a RES
instruction that has same address as the CTD instruction is
executed or the count is incremented greater than or equal to
+32,767 with a CTU instruction.
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Increments the accumulated value at each false-to true transition
and retains the accumulated value when the instruction goes false
or when power cycle occurs.
Fig : Count Up
CTD: Count Down
Decrements the accumulate value at each false-to true transition
and retains the accumulated value when the instruction goes false
or when power cycle occurs.
Addressing of counter:
21
RESET: --(RES)--
Reset the accumulated value and status bits of a timer or counter.
A C5:0
-------[ ]---------------------(RES)--------------------------
When A is true than counter C5:0 is reset.
2. OR logic:
Y1=X0+X1
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Fig 3.6: OR logic ladder diagram
3. NOT logic:
Y3=X0
4. NAND logic:
Y0=X0.X1
23
Fig : XOR logic ladder diagram
7. X-NOR logic:
Y2=X0 + X1
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Fig : Push button logic ladder diagram
Here button a is start push button and b is stop push button and x
is binary type output.
STEP: 2
Making input side sensor logic:
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Here we use one Exit sensor and one counter which is CTD
(counter down) and take CTD preset value 5.
STEP: 4
Making parking light (LED) control logic:
Operation:
After program making ,it is download in plc. This program store
in plc memory.
When we push the start button than plc scan the input means
input condition of button A is true(1).so the binary output is also
true(1).
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When start button release than input condition of button A is
false. But the start button and binary input both are in parellel.
The address of binary output and binary input are same so we get
continuous supply.
Binary output we can use as a input in next step ,its status is true
for sense the entering car we use a input sensor and for counting
the car we use a CTU because accumulator value less than preset
value.
Similarly when fifth car enter than CTU count it’s accumulator
value .Now counter done bit is true because CTU address is C5:0
and take its preset value 5 because parking place capacity is 5.
When first car enter then input sensor status goes true . Due to
this CTU count one in it’s accumulator value .but counter done bit
does not true accumulator value equal to preset value.
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Fig : operation of input sensor logic
When done bit goes true than LED output is true so parking light
is on.
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Now both counter’s accumulator value less than preset value so
done bit goes false and parking light off .
APPLICATIONS OF PLC:
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SCADA
(SUPERVISORY CONTROL AND DATA ACQUISITION)
INTRODUCTION
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1. One or more field data interface devices, usually RTUs, or PLCs,
which interface to field sensing devices and local control
switchboxes and valve actuators
2. A communications system used to transfer data between field
data interface devices and control units and the computers in
the SCADA central host. The system can be radio, telephone,
cable, satellite, etc., or any combination of these.
3. A central host computer server or servers (sometimes called a
SCADA Center, master station, or Master Terminal Unit (MTU)
4. A collection of standard and/or custom software [sometimes
called Human Machine Interface (HMI) software or Man
Machine Interface (MMI) software] systems used to provide
the SCADA central host and operator terminal application,
support the communications system, and monitor and control
remotely located field data interface devices.
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Fig : Typical SCADA System
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ARCHITECTURE:
Hardware Architecture:
The generally SCADA system can be classified into two parts:
Clint layer
Data server layer
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The Clint layer which caters for the man machine interaction. The
data server layer which handles most of the process data
activities. The SCADA station refers to the servers and it is
composed of a single PC. The data servers communicate with
devices in the field through process controllers like PLCs or RTUs.
The PLCs are connected to the data servers either directly or via
networks or buses. The SCADA system utilizes a WAN and LAN
networks, the WAN and LAN consists of internet protocols used
for communication between the master station and devices. The
physical equipments like sensors connected to the PLCs or RTUs.
The RTUs convert the sensor signals to digital data and sends
digital data to master unit.
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Software Architecture:
Most of the servers are used for multitasking and real time
database. The servers are responsible for data gathering and
handling. The SCADA system consists of a software program to
provide trending, diagnostic data, and manage information such
as scheduled maintenance procedure, logistic information,
detailed schematics for a particular sensor or machine and expert
system troubleshooting guides. This means the operator can sea a
schematic representation of the plant being controlled.
EX: alarm checking, calculations, logging and archiving; polling
controllers on a set of parameter, those are typically connected to
the server.
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Fig : Human machine interface
For example: The tank water level alarm is set 60% and 70%
values. If the water level reaches above 60% the alarm gives
normal warning and if the water level reach above 70% the alarm
gives critical warning.
Monitoring/Control:
The SCADA system uses different switches to operate each device
and displays the status at
the control area. Any part of the process can be turned ON/OFF
from the control station using these switches. SCADA system is
implemented to work automatically without human intervention
but at critical situations it is handled by man power.
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DESIGN SCADA WITH INTOUCH WONDERWARE SOFTWARE
AND APPLICATION:
SCADA is main interface between your control system and
Operator. Maximum data and
features available on SCADA give you better control and clarity
about the system. SCADA
needs to read data from various devices like:-
PLC/Controllers
RTU
Energy meters/Load managers/Data loggers
Field instruments like Flow meters and positioners
Each of above data communicates with SCADA on various
protocols . SCADA reads or
writes the data in format of tags.
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Fig : Animation Link Selection Dialog Box
TOUCH LINK
A. User Input touch links:
Discrete: Used to control the value of a discrete tagname.
Analog: Used to input the value of an analog (integer or real)
tagname.
String: Used to create an object into which a string message may
be input.
B. Sliders touch links:
Vertical& Horizontal:
we can move the slider position horizontally or vertically.
C. Touch Pushbutton links:
Discrete Value:
39
Used to make any object or symbol into a pushbutton that
controls the state of a discrete tagname. Pushbutton actions can
be set, reset, toggle, momentary on (direct) and momentary off
(reverse) types.
Action:
Allows any object, symbol or button to have up to three different
action scripts linked to it; On Down, While Down and On Up.
Show Window:
Used to make an object or symbol into a button that opens one or
more windows when it is clicked or touched.
Hide Window:
Used to make an object or symbol into a button that closes one or
more windows when it is clicked or touched.
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The line, fill, and text colour of an object or symbol can be linked
to the value of an analog tag name (integer or real) or an analog
expression. Five value ranges are defined by specifying four
breakpoints. Five different colours can be selected which will be
displayed as the value range changes.
Discrete Alarm:
The text, line, and fill colour of an object can all be linked to the
alarm state of a tag name, Alarm Group, or Group Variable. This
colour link allows a choice of two colours; one for the normal
state and one for the alarm state of the tag name. This link can be
used for both analog and discrete tag names. If it is used with an
analog tag name, it responds to any alarm condition of the tag
name
Analog Alarm:
The text, line, and fill colour of an object can all be linked to the
alarm state of an analog tag name, Alarm Group, or Group
Variable. Allows a specific colour to be set for the normal state as
well as a separate colour for each alarm condition defined for the
tag name.
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OBJECT SIZE LINKS:
We use Object Size links to vary the height and/or width of an
object according to the value of an analog (integer or real) tag
name or analog expression. Size links provide the ability to
control the direction in which the object enlarges in height and/or
width by setting the "anchor" for the link. Both height and width
links can be attached to the same object.
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Fig : vertical fill dialog box
LOCATION LINKS:
We use Location Links to make an object automatically move
horizontally, vertically, or in both directions in response to
changes in the value of an analog tag name or expression
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Blink:
Used to make an object blink based on the value of a discrete tag
name or expression.
Orientation:
Used to make an object rotate based on the value of a tag name or
expression.
Disable:
Used to disable the touch functionality of objects based on the
value of a tag name or expression.
VALUE DISPLAY LINKS:
Value Display Links provide the ability to use a text object to
display the value of a discrete, analog, or string tag name. There
are three types:
Discrete :
Uses the value of a discrete expression to display an On or Off
user defined message in a text object.
Analog:
Displays the value of an analog expression in a text object.
String:
Displays the value of a string expression in a text object.
APPLICATIONS OF SCADA:
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Oil & Gas
Pharmaceutical
Power, Utilities & Generation
Transportation
Water & Wastewater
ADVANTAGES:
The SCADA system provides on board mechanical and
graphical information
The SCADA system is easily expandable. We can add set of
control units and sensors according to the requirement.
The SCADA system ability to operate critical situations.
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CONCLUSION:
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