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A Presentation on

SOFCON INDIA PVT. LTD.


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contents
Company Profile
Industrial Automation PLC SCADA
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Company Profile

Sofcon Group Companie s


Sofcon 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 networking
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Facilities for Live Exposure

Achievements Till-date
Trained 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.
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Industrial Automation

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.
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Automation Principle

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Why Automation required in Industry ?


Productivity

Total Auto.

Manufacturing Competitiveness Solution

Quality

Plant

Labour Cost
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History of Automation

Programmable Logic Controller Hard wired logic Control Manual Control

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Manual Control
All

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.
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Hard wired logic control


The

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 troubleshooting
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MAJOR PARTS OF AUTOMATION

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Programmable Logic Controllers

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Introduction of PLC
PLC 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.

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Advantages of PLC
On

line/Off line modification Ease of maintenance Large quantity of contacts Greater life & reliability Tremendous flexibility Shorter project time Easier storage and documentation

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TYPES OF PLC

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Small modular PLC

mounted on rail, 24V supply cheaper not water-proof I/0 can be expanded

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Compact PLC

Monolithic (one-piece) construction Fixed casing Fixed number of I/O (most of them binary) No process computer capabilities
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P L C Components

Input Output Modules Central Processing Unit Power Supply Bus system Programming Device

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P L C Working

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Input Devices
Pushbuttons
Selector Switches Photoelectric Sensors Proximity Sensors Relay Contacts
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Output Devices
Valves Solenoids Lights Horns Meters

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Matching the Digital and Analog world

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P L C : Power Supply
The 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.
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Configuration Of PLC : Allen Bradley

CPU

I/O Modules

Power Supply

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PLC in Cabinet
cpu1 redundant field bus connection cpu2

serial connections
redund. field bus

inputs/outputs

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Hardware over view of PLC

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PLC Program Scan


Self Check Scan Inputs

Update Outputs

Execute Code
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SCAN RATE/SCAN TIME

Scan Cycle Depends upon no. of I/Os

More I/Os More scan time


Application 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 ms
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Troubleshooting in PLC

LED1 LED2 LED3 LED4 LED5

DC power ON Processor fault Memory fault I/O fault Stand by battery low
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Various Brands Of PLC

Allen Bradley Siemens Modicon Mitsubishi GE Fanuc Omron

USA Germany France Japan USA Japan


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Global players

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Application Of Automation

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Ladder Basics

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.

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Contact Symbols

It is true when input status is 1

It is true when input status is 0

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AND Gate

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OR Gate

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NOT Gate

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Supervisory Control & Data Acquisition Systems

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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.
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Features of SCADA
Dynamic process graphic Real-time and Historical trending Alarms Recipe Management Security Device connectivity Script for logic development Networking
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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.
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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.

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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.
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Recipe Management

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.

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Security

To avoiding access.

unauthorized

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.

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Device Connectivity

The SCADA software needs device driver software for communication with PLC. More the driver software available better is the device connectivity.

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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.

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HMI System

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Example of SCADA

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Usefulness of SCADA

Production Dept. Quality Dept. Maintenance Dept. Engineering Dept. Manufacturing Dept.

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Some of the Leading SCADA Software


Wonderware : InTouch Intellution : iFix (Earlier Fix DMACS) Allen Bradley : RS View (Earlier Control View) Siemens : WinCC (Earlier Coros LS /B ) GE Fanuc : Cimplicity

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Typical Industry Application

Apart from manufacturing process, SCADA software are being used very effectively in water supply and management. The functionality includes.
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Typical Industry Application


Control of Substations Load shedding Metering Downtime analysis Dispatch and assessment

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Any Queries?

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