Summer Training -PLC & SCADA

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Industrial Automation

MACHINE MACHINE CONTROL SYSTEM CONTROL SYSTEM INFORMA

INFORMATION TION TECHNOLOGYTECHNOLOGY

Automation is basically the delegation of Automation is basically the delegation of

human control human control

function to technical equipment for function to technical equipment for

•

•Increasing ProductivityIncreasing Productivity

•

• Increasing Increasing QualityQuality

•

• Reducing CostReducing Cost

•

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What is

Industrial

Automation ..?

Automation is encompassing virtually every

walk of life

walk of life.

.

Automation solutions are required right

Automation solutions are required right from

from

agricultural to space technology

agricultural to space technology.

.

Plant Automation is the necessity for the

manufacturing industry to survive in

manufacturing industry to survive in today’

today’ss

globally competitive

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IT

IS ALSO AUTOMA

TION

Feedback(Eyes) Feedback(Eyes) Processor (Brain) Processor (Brain) controlling unit(Hand) controlling unit(Hand)

When Human Operator

When Human Operator can operate can operate the machine ,taking Feedback of the machine ,taking Feedback of aa Machinery performance and he

Machinery performance and he can change or can change or adjust according adjust according to rto requirement,equirement, that why it also called as Automation.

that why it also called as Automation.

Thus ,we can define Automation Thus ,we can define Automation Any

Any systematic operationsystematic operation requiredrequired intelligenceintelligence and as well asand as well as monitoring

monitoring action.action. Don’t Surprise Don’t Surprise Output Output action unit action unit (Leg) (Leg)

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Scope of Automation in industries

•

Power & Steel plant

•

Chemical

•

Paint

•

Gas & oil

•

Automobile Industries

•

Mobile manufacturing industries

•

Textile industry

•

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Industrial

Industrial Automa

Automation

tion

•

PLC

•

SCADA

•

PID Controller

•

Industrial Instrumentation

•

Motor(AC)

•

Relay & Contactor ,electrical device’

Relay &

Contactor ,electrical device’s symbols

s symbols

•

Drives (AC)

•

HMI

•

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ELECTRONIC CONTROLLER

TIMER TIMER

It is used for time delay generation It is used for time delay generation for the operation of different

for the operation of different Machinery

Machinery

COUNTER COUNTER

It is used for counting the It is used for counting the no.

no. of of eventevent

PID Controller PID Controller

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Thermocouple Thermocouple PID Controller PID Controller VFD VFD

Temperature

controlling

by the use of PID

controller in

Industry

Blower Blower

Analog Input Signal

Analog Input Signal (FEEDBACK)(FEEDBACK)

Regulated Controlled Signal ( Output) Regulated Controlled Signal ( Output)

Frequency controlled Frequency controlled Power supplied to Power supplied to Blower Motor Blower Motor

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Limitation of Electronic Controller in a Industry

In industry where

In industry where large number large number of a of a Timer , Timer , CounterCounter, PID, Relay, PID, Relay,,

Switches and etc

Switches and etc ,,which all makes the entire system costly andwhich all makes the entire system costly and

complicated .

Thus, there is need of One Controller which can monitor the entire Thus, there is need of One Controller which can monitor the entire system

system And

And also generate also generate delay and count delay and count a eventa event Easy to be program , modify whenever needed Easy to be program , modify whenever needed

All this feature

All this feature are add up are add up in a one in a one controller PLC controller PLC (Programmable(Programmable

Logic Controller)

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History of Automation

•

Manual control system

•

Pneumatic control system

•

Hard wired logic control system

•

Electronic contr

ol using

logic gate

•

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A PLC is a micro processor based solid state / computerized

A PLC is a micro processor based solid state / computerized industrialindustrial

computer

computer that performs discrete or sequential logic in a factory environment.that performs discrete or sequential logic in a factory environment.

It was originally developed to replace

It was originally developed to replace mechanical relays, timers, counters.mechanical relays, timers, counters.

PLCs are used successfully to

PLCs are used successfully to execute complicated control operationsexecute complicated control operations in ain a plant.

plant.

Programmable Logic Controller

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History of PLC

The PLC was i

The PLC was invented in response to the needs nvented in response to the needs of the American automotiveof the American automotive manufacturing industry.

manufacturing industry.

Programmable logic controllers were initially adopted by

Programmable logic controllers were initially adopted by the automotive industry wherethe automotive industry where software revision

software revision replaced the re-wiring replaced the re-wiring of hard-wired of hard-wired control panels when control panels when productionproduction models changed.

models changed.

In 1968 GM Hydramatic (the

In 1968 GM Hydramatic (the automatic transmission division of automatic transmission division of General MotorsGeneral Motors) issued a) issued a request for pro

request for proposal posal for an electronic replacement for an electronic replacement for hard-wired rfor hard-wired relay systems. Thelay systems. The winninge winning proposal came from Bedford

proposal came from Bedford AssociatesAssociates of

of Bedford, MassachusettsBedford, Massachusetts.. The first PLC,

The first PLC, designated the 084 because it designated the 084 because it was Bedford Aswas Bedford Associates' eightysociates' eighty-fourth project,-fourth project, was the result.

was the result. Bedford Bedford Associates started a Associates started a new companynew company

dedicated to developing, manufacturing, selling, and servicing

dedicated to developing, manufacturing, selling, and servicing this new product:this new product: Modicon, which stood for Modular Digital C

Modicon, which stood for Modular Digital Controllerontroller. One of the people . One of the people who worked on thatwho worked on that project was

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Global Player in

Global Player in a

a Automation Industry

Automation Industry

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Progr

amming In a

PLC

User have

User have a a multiple Choice multiple Choice for for programming programming a a PLCPLC

Ladder logic

Functional Block Diagram

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Ladder Logic

Ladder Logic Progr

Programming

amming

It is a easier way of Programming the PLC. It is a easier way of Programming the PLC.

So that Engineer m

So that Engineer must be concerned only on proceust be concerned only on procedure and functional dure and functional of theof the machinery design

machinery design For this knowledge of

For this knowledge of basic Electronic Circuit is sufficient.basic Electronic Circuit is sufficient.

For Example For Example

Basic Gate Logic Basic Gate Logic

OR Gate OR Gate A A B B Output Output A A B B Output Output Electrical Circuit Electrical Circuit Ladder Logic Ladder Logic

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AND

AND Gate Gate AA OutputOutput

A A BB _Output_Output B B Electrical Electrical Circuit Circuit Ladder Logic Ladder Logic NOT gate NOT gate A A Output Output A Output A Output Electrical Circuit Electrical Circuit Ladder Logic Ladder Logic

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Motion Control System

VFD VFD Induction Motor Induction Motor Stepper Drive Stepper Drive Stepper Motor Stepper Motor We can operate these

We can operate these Drive through

Drive through Keypad , external Keypad , external Switch and also Switch and also through PLC through PLC

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Industrial Robotic is also the part of Automation Industry

Industrial robotic is the finest example of

Industrial robotic is the finest example of motion control systemmotion control system, One, One robot required one controller for the specific operation but

robot required one controller for the specific operation but whenwhen

multiple robot working together

multiple robot working together thus we required no. of PLCthus we required no. of PLC connected together by Master PLC, so that entire process can be connected together by Master PLC, so that entire process can be synchronized

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SCADA

Supervisory Control and

Supervisory Control and Data Acqu

Data Acquisition

isition

Supervisory means

Supervisory means MonitoringMonitoring

entire system through entire system through GUI representation

GUI representation

of working Status ,of the of working Status ,of the entire system

entire system

Control means Controlling Control means Controlling the entire System such as the entire System such as ON/OFF operation ON/OFF operation ,, Speed controlling, Speed controlling, temperature Controlling temperature Controlling Data Acquisition Data Acquisition mean

mean collectingcollecting

data Information

data Information fromfrom Different controller, Different controller, Sensor , Drives , Motor Sensor , Drives , Motor which are connected at which are connected at distance through wire , distance through wire , Ethernet , wireless

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PLC is just like a

PLC is just like a Black BoxBlack Box, internal operation of its, internal operation of its user can`t see until the entire process complete or halt user can`t see until the entire process complete or halt thethe System…Thus we required

System…Thus we required GUIGUI(Graphical User Interface)(Graphical User Interface) Representation of the entire process……..

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Main

Main feature

feature of

of SCADA

SCADA

•

•GUI is designed by simpleGUI is designed by simple Drag and Paste concept.Drag and Paste concept. •

•Tagging and CodingTagging and Coding is done by considering programming bit .is done by considering programming bit . •

•On On SCADA SCADA ,we ,we can can monitor monitor Real Real Time Time operationoperation andand Historical Trend .Historical Trend . •

•Alarm triggeringAlarm triggering which also used in this system , it which also used in this system , it trigger trigger when certainwhen certain

task complete

task complete or or sudden brake of a system.sudden brake of a system.

•

•Recipe management ,Recipe management ,it provide the operator multiple choice for mixing theit provide the operator multiple choice for mixing the

variety of chemical and solution. variety of chemical and solution.

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We

We can also monitor can also monitor the Real time the Real time operation and theoperation and the process on Graph .

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In Industry SCADA were designed on

Computer

System , and display may be on computer screen,

LCD Display or Projector

Here w

Here we can e can see, see, all the all the sensor , sensor , chemical tank, filling prchemical tank, filling process , ocess , temperature temperature ,ON,ON /OFF status of Motor .All this thing, it has being monitor on the PC screen and big /OFF status of Motor .All this thing, it has being monitor on the PC screen and big LCD Screen

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HMI

Human Machine Interface Human Machine Interface

It have some major feature of SCADA ,HMI it is basically a

It have some major feature of SCADA ,HMI it is basically a controlcontrol

display screen

display screen were operator can monitor and control the machinerywere operator can monitor and control the machinery and it is portable and can easily installed on the Machine itself

and it is portable and can easily installed on the Machine itself

HMI It was designed

for the specific task

operation on the

machine

and SCADA is for

entire Plant

operation

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Industrial Networking

Eternet, Device net,Modbus , Profibus cable are used for Eternet, Device net,Modbus , Profibus cable are used for connecting entire Controller , Sensor , PLC and SCADA connecting entire Controller , Sensor , PLC and SCADA

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Industrial Sensor

It is basically are of two

It is basically are of two typetype Digital Sensor Digital Sensor it has switching b/w it has switching b/w ( 0,24V)( 0,24V) Analog Sensor Analog Sensor

It is basically are of two

It is basically are of two typetype Current type analog Sensor Current type analog Sensor

(4mA

(4mA——20mA)20mA)

Voltage type analog Sensor Voltage type analog Sensor

(0

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Advantag

e of

Implementation of

automation in Industry

Increase In Production Increase In Production Reliability in operation Reliability in operation

Flexibility in control techniques Flexibility in control techniques

Flexibility in programming and reprogramming in the plant Flexibility in programming and reprogramming in the plant Large quantity of I/O s are connected

Large quantity of I/O s are connected Online/ offline modifications

Online/ offline modifications

Cost effective for controlling complex systems Cost effective for controlling complex systems In-house simulation & testing of project

In-house simulation & testing of project Speed in operation

Speed in operation

Ability to communicate with computer systems in the plant. Ability to communicate with computer systems in the plant. Ease of maintenance / troubleshooting

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SCOPE

SCOPE OF AUTOMAOF AUTOMATIONTION

In Aeronautic and Space Application, In Aeronautic and Space Application, where large amount of a Controlling where large amount of a Controlling unit

unit are are used used for for connecting connecting differentdifferent device that are working systematic device that are working systematic manner

manner

Smooth functioning of the Delhi Metro train is a Smooth functioning of the Delhi Metro train is a example of a motion control system .

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SCOPE

SCOPE OF AUTOMAOF AUTOMATIONTION

In the Research Lab such as In the Research Lab such as CERN,NASA,ISRO,DRDO and etc CERN,NASA,ISRO,DRDO and etc

Where very small unit of machine to Where very small unit of machine to the ve

the very hery heavy Macavy Machinery hinery UnitUnit designed are interlink together , A designed are interlink together , A to Z controlling in came under to Z controlling in came under industrial Automation.

industrial Automation. In Heavy industry such as Steel ,Automobile ,In Heavy industry such as Steel ,Automobile , and Food

and Food industry where industry where the man are the man are not ablenot able to

to work work in in a a such such hostile hostile condition ,condition ,thusthus sensor, controller & PLC are diploid there and sensor, controller & PLC are diploid there and monitoring & controlling is done from SCADA

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Industrial

Automation is

the

End Consumer

of the

Engineering field

.

In Industry and Research Lab

All the Mechanical machinery from small to large such as All the Mechanical machinery from small to large such as Hydraulic system, pneumatic system, Induction motor are Hydraulic system, pneumatic system, Induction motor are consumes in

consumes in the the Automation Automation industryindustry

Relay ,Contactor and large Amount of Switch Relay ,Contactor and large Amount of Switch

Gear(MCB,MCCB,OLR ,Push Button) are also consumes in this Gear(MCB,MCCB,OLR ,Push Button) are also consumes in this industry

industry

Industrial sensor (Proximity ,IR Sensor , Level sensor) & Industrial sensor (Proximity ,IR Sensor , Level sensor) & instrument (Pressure Switch , limit Switch, Flow Meter) instrument (Pressure Switch , limit Switch, Flow Meter) are also consumes in this

are also consumes in this

Embedded product such counter , timer, PID controller and Embedded product such counter , timer, PID controller and electronic Regulator and PLC are also consumes in the

electronic Regulator and PLC are also consumes in the automation

automation Mechanical

Mechanical

For connecting different device , controller , PLC and SCADA For connecting different device , controller , PLC and SCADA so that they can communicate with each other thus

so that they can communicate with each other thus Industrial networking requirement is essential

Industrial networking requirement is essential Electrical Electrical Instrumentation Instrumentation Electronic Electronic Information Technology Information Technology