INDUSTRIAL AUTOMATION INTERNSHIP

A INTERNSHIP REPORT

Submitted by

PARMAR DEVANSHU SHAILESHBHAI

216840309002

In partial fulfilment for the award of the degree of

DIPLOMA IN ENGINEERING

In
ELECTRICAL ENGINEERING

GROW MORE FACULTY OF DIPLOMA ENGINEERING

GUJARAT TECHNOLOGICAL UNIVERSITY,

AHMEDABAD
May, 2023

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GROW MORE FACULTY OF DIPLOMA ENGINEERING .

HIMMTNAGAR

CERTIFICATE

This is to certify that the project report submitted along with the project entitled

Industrial Automation has been carried out by PARMAR DEVANSHU S. under my

guidance in partial fulfillment for the Diploma Engineering in Electrical Engineering 5th

Semester of Gujarat Technological University, Ahmadabad during the academic year

2023- 24.

PRO.SOHIL LUHAR. PRO.RAMESH PRAJAPATI

Internal Guide Head of Department

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Date: / /2023

TO WHOM IT MAY CONCERN

This is to certify that PATEL AVINASH D, a student of GROW MORE

FACULT OF DIPLOMA ENGINEERING.HIMMTNAGAR has successfully completed
his internship in the field of Industrial Automation from to (Total number of Weeks: 06 )
under the guidance of M/S Jigna Dave .His internship activities include During the period
of her/ his internship program with us, he / she had been exposed to different processes and
was found diligent, hardworking and inquisitive. We wish him every success in his life and
career. For SOFCON INDIA PVT. LTD.
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GROW MORE FACULTY OF DIPLOMA ENGINEERING.

HIMMTNAGAR

DECLARATION
We hereby declare that the Internship report submitted along with the Internship

Industrial Automation entitled submitted in partial fulfillment for the Diploma

Engineering in Electrical Engineering to Gujarat Technological University, Ahmedabad,

is a bona fide record of original project work carried out by me SOFCON INDIA PVT.

LTD. at under the supervision of M/S Jigna Dave and that no part of this report has been

directly copied from any students’ reports or taken from any other source, without

providing due reference.

Name of the Student Sign of Student

PARMAR DEVANSHU S.
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ACKNOWLEDGEMENT

I/We wish to express our sincere gratitude to our External guide M/S JIGNA
DAVE for continuously guiding me at the company and answering all my doubts
with patience.

We also thank our parents, friends and all the members of the family for their
precious support and encouragement which they had provided in completion of our
work. In addition to that, we would also like to mention the company personals who
gave us the permission to use and experience the valuable resources required for the
internship.

Thus, In conclusion to the above said, we once again thank the staff members of
SOFCON INDIA PVT. LTD. For their valuable support in completion of the project.

Thank You
PARMAR DEVANSHU (216840309002)
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ABSTRACT

Any Industrial Automation there many instruments wired together in a network. In

order to make them functioning Programmable Logic controllers (PLC) are used.
Programmable Logic Controllers are industry based computers that are used to
monitor inputs and control the output based on the logic state of the input.
Sometimes the system is placed in remote locations and in order to control the
functions of such systems. This is known as Supervisory Control and Data
Acquisition System (SCADA).SCADA is system that enables to control, monitor
and coordinate devices and components in real time from a remote location with
acquisition of data for analysis and planning from one central location.
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Table of Contents

Acknowledgement........................................................................................................
Abstract........................................................................................................................

List of Figures..............................................................................................................

Chapter 1 Automation.................................................................................................

* history.....................................................................................................................

* Automation.............................................................................................................

* Advantages of automation........................................................................................

* Disadvantages of automation...................................................................................

* Parts of automation..................................................................................................

Chapter 2 Programmable logic controller.................................................................

* Programmable logic controller..................................................................................

* PLC (Allen Bradley)...............................................................................................

* Programming language used in a plc......................................................................

* Symbols used in ladder logic programming….........................................................

* Components of PLC...............................................................................................

* Input/output devices................................................................................................

* Hardware overview….............................................................................................

* Benefits....................................................................................................................

* Programming of PLC................................................................................................

* Simple Ladder Logic.................................................................................................

* Communication of PLC with PC..............................................................................

* PLC instruction..........................................................................................................
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* Counters.....................................................................................................................

* Counters Programming…..........................................................................................

* Commands for Comparison.......................................................................................

Chapter 3 Supervisory Control and Data acquisition..............................................

* SCADA.......................................................................................................................

* Features of SCADA....................................................................................................

* Potential benefits of SCADA….................................................................................

* Application of SCADA..............................................................................................

* Benefits of intouch.....................................................................................................

* Programming with intouch........................................................................................

Chapter 4 :- Conclusion…………………………………………………………..

References.....................................................................................................................
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CHAPTER: 1

AUTOMATION

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2023-24

* HISTORY

Control engineering has evolved over time. In the past humans were the main
method for controlling a system. More recently electricity has been used for control
and early electrical control was based on relays. These relays allow power to be
switched on and off without a mechanical switch. It is common to use relays to
make simple logical control decisions. The development of low cost computer has
brought the most recent revolution, the Programmable Logic Controller (PLC). The
advent of the PLC began in the 1970s, and has become the most common choice for
manufacturing controls. PLCs have been gaining popularity on the factory floor and
will probably remain predominant for some time to come. Most of this is because of
the advantages they offer.

 Cost effective for controlling complex systems.

 Flexible and can be reapplied to control other systems quickly and easily.

 Computational abilities allow more sophisticated control.

 Trouble shooting aids make programming easier and reduce downtime.

 Reliable components make these likely to operate for years before failure

The term SCADA stands for Supervisory Control and Data Acquisition. A SCADA
system is a common process automation system which is used to gather data from
sensors and instruments located at remote sites and to transmit and display this data
at a central site for either control or monitoring purposes. The collected data is
usually viewed on one or more SCADA Host computers located at the central or
master site.

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* AUTOMATION

Automation or automatic control is the use of various control systems for

operating equipment such as machinery, processes in factories, boilers and heat
treating ovens, switching in telephone networks, steering and stabilization of ships,
aircraft and other applications with minimal or reduced human intervention. Some
processes have been completely automated.

The biggest benefit of automation is that it saves labor however, it is also used to
save energy and materials and to improve quality, accuracy and precision.

The term automation, inspired by the earlier word automatic (coming from
automaton), was not widely used before 1947, when General Motors established the
automation department. It was during this time that industry was rapidly adopting
feedback controllers, which were introduced in the 1930s.

Automation has been achieved by various means including mechanical, hydraulic,

pneumatic, electrical, and electronic and computers, usually in combination.
Complicated systems, such as modern factories, airplanes and ships typically use all
these combined techniques

.
History of Automation:-In the ancient times people worked by hand. They
made every tasks, every works without any help. Later they began to do some
simple (and later more complicated) machines, e.g. Water wheels for lifting water
from channels, mills (water and wind mills) for milling corns, etc. They began to
use animals to give their force, their power to get work machines, vehicles, etc.
In the Sixth century the machines were able to do many tasks. Steam engines gave
the mechanical energy to machines, but the man had to control every machine.
Control consists of some activities:
 Set the appropriate device (modify the setting of fuel valve)
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2023-24

 Observe the phenomena (speed of machine, pressure of

steam, temperature of water, etc.),
 compute (decide) the needed activity (growing or reducing the
amount of fuel ),

* Advantages of Automation
 The main advantages of automation are:-

 Increased through output or productivity.

 Improved quality or increased predictability of quality.

 Improved robustness (consistency), of processes or product.

 Increased consistency of output.

 Reduced direct human labor costs and expenses.

* Disadvantages of Automation
 The main disadvantages of automation are:-

 Causing unemployment and poverty by replacing human labor.

 Security Threats/Vulnerability: An automated system may

have a limited level of intelligence, and is therefore more susceptible
to committing errors outside of its immediate scope of knowledge
(e.g., it is typically unable to apply the rules of simple logic to general
propositions).

 Unpredictable/excessive development costs: The research and

development cost of automating a process may exceed the cost saved
by the automation itself.

 High initial cost: The automation of a new product or plant

typically requires a very large initial investment in comparison with
the unit cost of the product, although the cost of automation may be
spread among many products and over time.
 CHAPTER: 02
PROGRAMABLE LOGIC CONTROLER
LOGIC INTERFACE BETWEEN INPUT AND OUTPUT TO PROCESS THE DESIRED L

Figure

* TYPES OF PLC

a) Compact type

b) Modular type

1. COMPACT TYPE
a) Slots are not available
b) I/O cannot be varied
c) Also compact in its size

2. MODULAR TYPE
a) Slots are available

⑤
* PROGRAMMING LANGUAGE USED IN A PLC
The Ladder Logic is the most commonly used PLC programming language.

* Ladder Diagram (LD)

Traditional ladder logic is graphical programming language. Initially
programmed with simple contacts that simulated the opening and closing of
relays, Ladder Logic programming has been expanded to include such
functions as counters, timers, shift registers, and math operations.

Figure

* FILE TYPE: FILE NO.: SLOT NO. *WORD NO. /BIT No.
I.e. For Input:-

I:0.0/0,I:0.0/1

And so on….

For Output:-

O0:0.0/0,O0:0.0/1

And so on…

⑥
* SYMBOLS USED IN LADDER LOGIC PROGRAMMING

Figure

* COMPONENTS OF A PLC

1. Power Supply:-
Provides the voltage needed to run the primary PLC components 24vDC, 220vAC, and
110ac

2. Communication:-
The wiring diagram shows the inputs and outputs connected directly
(hard wired) to the PLC. The devices shown are on/off or digital in nature but the
signal to the PLC is analog. Many commonly used devices conform to a 4-20 mA
standard whereby signals of 4mA and 20mA form respectively the minimum and
maximum values of an analog signal. With analog devices, a separate cable needs to
be run between the end device and the control system because only a single analog
signal can be represented on the circuit. The 4-20 mA standard is slowly being
replaced by network or fieldbus communications. Fieldbus is a multi-drop digital
two- way communication link between intelligent devices. Fieldbus allows the
connection of a number of sensors all located in the same area to the same cable.
Fieldbus comes in many varieties depending on the manufacturer and application.
Examples include ASibus, Provirus, Device net and Modbus. A more recent trend is
the development of

⑦
Industrial Ethernet which has the capacity to transport large quantities of data not
only for process control but also to integrate the process with management
information systems.

3. Input Modules:-

 Provides signal conversion and isolation between the internal logic-

 Level signals inside the PLC and the field’s high level signal.

 The I/O interface section of a PLC connects it to external field devices.

 The main purpose of the I/O interface is to condition the various

signals received from or sent to the external input and output devices.

 Input modules converts’ signals from discrete or analog input

devices to logic levels acceptable to PLC’s processors.

* Discrete Input:-

A discrete input also referred as digital input is an input that is either ON or OFF is
connected to the PLC digital input. In the ON condition it is referred to as logic 1 or
logic high and in the OFF condition may be referred to as logic o or logic low. It can
be toggle switch, push button etc.

* Analog input:-

An analog input is an input signal that has a continuous signal. Typical inputs may
vary from 0 to 20mA, 4 to 20mAor 0 to10V. Below, a level transmitter monitors the
level of liquid in the tank. Depending on the level TX, the signal to the PLC can
either increase or decrease as the level increases or decreases. E.g. temperature and
pressure related instruments etc.

⑧
4.Output Modules:-
Output modules converts signal from the processor to levels capable of driving the
connected discrete or analog output devices.

* Analog Output:-
An analog output is an output signal that has a continuous signal. Typical outputs
may vary from 0 to 20mA, 4 to 20mAor 0 to10V.

* Digital Output:-
A discrete output is either in an ON or OFF condition. Solenoids, contactors coils,
lamps are example of devices connected to the Discrete or digital outputs. Below,
the lamp can be turned ON or OFF by the PLC output it is connected to.

5.Processor:

The processor module contains the PLC’s microprocessor, its supporting circuitry,
and its memory system. The main function of the microprocessor is to analyze data
coming from field sensors through input modules, make decisions based on the
user’s defined control program and return signal back through output modules to the
field devices. Field sensors: switches, flow, level, pressure, temp. Transmitters, etc.
Field output devices: motors, valves, solenoids, lamps, or audible devices.

Figure

⑨
* INPUT/OUTPUT DEVICES

INPUTS
OUTPUTS
 Switches and
Pushbuttons  Valves
 Sensing Devices
 Limit Switches  Motor Starters
 Photoelectric  Solenoids
Sensors
 Proximity  Actuators
Sensors
 Horns and Alarms
 Condition Sensors
 Stack lights
 Encoders
 Pressure Switches  Control Relays
Level Switches
 Counter / Totalizer
 Temperature
 Pumps
Switches
 Vacuum Switches  Printers
Float Switches  Fans

⑩
* HARDWARE OVERVIEW

The Micro Logic 1000 programmable controller is a packaged controller containing a

power supply, input circuits, output circuits, and a processor. The controller is
available in 10 I/O, 16 I/O and 32 I/O configurations, as well as an analog version
with 20 discrete I/O and 5 analog I/O.

The catalog number for the controller is composed of the following:

Figure

Figure

⑪
 * BENEFITS
a. Compact design

Let’s the Micro Logic 1000 controller thrive in limited panel space.

b. Choice of communication networks

An RS-232-C communication port is configurable for: DF1 protocol for direct
connection to a programming device or operator interface; DH-485 networking
through a 1761-NET- AIC converter; Device Net networking through a 1761-
NET-DNI interface; Ethernet/IP networking through a 1761-NET-ENI interface;
or for half-duplex slave protocol in SCADA applications.
c. Simple programming with your choice of programming device
You can program these controllers in familiar ladder logic with MicroLogix 1000
A.I. Series Software®, PLC 500 A. I. Series Programming Software, RSLogix
500™ Windows Programming Software, or the MicroLogix Hand-Held
Programmer (1761- HHP-B30). This symbolic programming language is based
on relay ladder wiring diagrams that simplify the creation and troubleshooting of
your control program.
d. Comprehensive instruction set

Over 65 instructions including simple bit, timer, and counter instructions, as

well as instructions for powerful applications like sequencers, high-speed
counter, and shift registers.
e. Fast

Execution time for a typical 500-instruction program is only 1.56 Ms.

f. Choice of languages

Software and documentation are available in 5 languages. The hand held

programmer has 6 languages built in.

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 * PROGRAMMING OF PLC

PLC programs are typically written in a special application on a personal

computer, then downloaded by a direct-connection cable or over a network to the
PLC. The program is stored in the PLC either in battery-backed-up RAM or some
other non- volatile flash memory. Often, a single PLC can be programmed to
replace thousands of relays.

In Allen Bradley PLC’s the logic used for the programming is ladder logic.
Ladder logic is a programming language that represents a program by a graphical
diagram based on the circuit diagrams of relay-based logic hardware. It is
primarily used to develop software for Programmable Logic Controllers (PLCs)
used in industrial control applications. The name is based on the observation that
programs in this language resemble ladders, with two vertical rails and a series of
horizontal rungs between them.
Ladder logic is widely used to program PLCs, where sequential control of a
process or manufacturing operation is required. Ladder logic is useful for simple
but critical control systems, or for reworking old hardwired relay circuits. As
programmable logic controllers became more sophisticated it has also been used in
very complex automation systems.

Figure 3.10

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 * SIMPLE LADDER LOGIC

If a path can be traced between the left side of the rung and the output, through

asserted (true or "closed") contacts, the rung is true and the output coil storage bit is
asserted (1) or true. If no path can be traced, then the output is false (0).

Electromechanical relays is considered "de-energized. Ladder logic has contacts

that make or break circuits to control coils. Each coil or contact corresponds to the
status of a single bit in the programmable controller's memory. Unlike
electromechanical relays, a ladder program can refer any number of times to the
status of a single bit, equivalent to a relay with an indefinitely large number of
contacts.
So-called "contacts" may refer to physical ("hard") inputs to the programmable
controller from physical devices such as pushbuttons and limit switches via an
integrated or external input module, or may represent the status of internal storage
bits which may be generated elsewhere in the program.
Each rung of ladder language typically has one coil at the far right. Some
manufacturers may allow more than one output coil on a rung.

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 -- ( ) -- a regular coil, energized whenever its rung is closed
-- (\) -- a "not" coil, energized whenever its rung is open
-- [ ] -- A regular contact, closed whenever its corresponding coil is energized
-- [\] -- A "not" contact, open whenever its corresponding coil is energized
The "coil" (output of a rung) may represent a physical output which
operates some device connected to the programmable controller, or may
represent an internal storage bit for use els

Example-:-

------ [ ] -------------- [ ] ----------------O---

Key Switch 1 Key Switch 2 Motor

“This is a logical AND.”

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 * COMMUNICATION OF PLC WITH PC

To make communication of PLC with PC following steps are noted down:

1) Connect PC and PLC via RS232 comport or Ethernet.

2) Then click on RS Linx icon, a window will appear as shown in fig below

Figure

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 2) RS LINKS CLASSIC WINDOW

Figure

3) In this window add drivers i.e. whether it is RS232 comport or Ethernet and
configure the drivers and closes the window.
4) Then click on icon RS who on the RS Links classic window, another window will
appear as shown in fig 3.5.3.4.
5) After opening the RS who window click on AB DF1-1 DH-485, the PLC is
running is shown on the window. Then close this window and double click on RS
Logix 500 starter.

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 Figure

6) When we double click on RS Logix 500 starter a window will appear as shown
in fig.

Figure

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 * PLC INSTRUCTIONS

There are various instructions which are useful for making ladder logic for PLC
programming. These are as follows:

* XIC (Examine if closed):

Use the XIC instruction in your ladder program to determine if a bit is ON. When
the instruction is executed, if the bit addressed is on (1), then the instruction is
evaluated as true. When the instruction is executed, if the bit addressed is off (0),
then the instruction is evaluated as false.

XIC (Examine if closed):

I/P O/P
0 0
1 1

Figure 1

Examples of devices that turn on or off include:

 A push button wired to an input (addressed as I: 0/4).

 An output wired to a pilot light (addressed as O: 0/2).

 A timer controlling a light (addressed as T4:3/DN).

* XIO (Examine if open):

Use the XIO instruction in your ladder program to determine if a bit is OFF.
When the instruction is executed, if the bit addressed is off (0), then the
instruction is evaluated as true. When the instruction is executed, if the bit
addressed is on (1), then the instruction is evaluated as false.

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 I/P O/P
0 1
1 0

Examples of devices that turn on or off include:

 Motor overload normally closed (N.C.) wired to an input (I: 0/10).

 An output wired to a pilot light (addressed as (O: 0/4).

 A timer controlling a light (addressed as T4:3/DN).

* OUTPUT ENERGIZE (OTE):

Use the OTE instruction in your ladder program to turn on a bit when rung
conditions are evaluated as true. An example of a device that turns on or off
is an output wired to a pilot light (addressed as O: 0/4).

Figure 3.13.3

OTE instructions are reset when:

• The SLC enters or returns to the REM Run or

REM Test mode or Power is restored.

• The OTE is programmed within an inactive or

false Master Control Reset (MCR) zone.

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 * TIMERS

 Timers are used to perform the timing operations. Time base is the
minimum value of time in second that can be taken by the timer.
Preset value is the total number of the seconds for which the timing
operation has to be done Accumulator starts increasing the time in
second’s up to the preset value. Up to the preset value of the
accumulator the enable bit of timer is high & the timer runs. When
accumulator reaches the preset value then the timer stops and the done
bit of the timer becomes high.

 The timer has following bits and these bits are useful in the operation of timer:

 EN- Enable- This bit will high when the input is given to the timer
 TT - Timer timing bit - This bit will be high during the timing process.
It remains high till accumulator value becomes equal to preset value
 DN – Done – This bit will be high when the timing process is ended. It
set to high when the accumulator value becomes equal to preset value.
 In Micrologix 1000 and 1100 PLC there are three types of timer’s i.e.

* TYPES OF TIMERS USED:-

1) TON Timer

2) T-OFF Timer

3) Retentive timer ON (RTO)

1. TON Timer

Use the TON instruction to turn an output on or off after the timer has been on for
a preset time interval. The TON instruction begins to count time-base intervals
when rung conditions become true. As long as rung conditions remain true, the
timer adjusts its accumulated value (ACC) each evaluation until it reaches the
preset value

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 Figure 3.14.1

(PRE). The accumulated value is reset when rung conditions go false, regardless of
whether the timer has timed out

2. T-OFF Timer:

Use the TOF instruction to turn an output on or off after its rung has been off for a
preset time interval. The TOF instruction begins to count time base intervals when
the rung makes a true- to-false transition. As long as rung conditions remain false,
the timer increments its accumulated value (ACC) based on the time base for each
scan until it reaches the preset value (PRE). The accumulated value is reset when
rung conditions go true regardless of whether the timer has timed out.

Figure 3.14.2

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 3. Retentive Timer (RTO):

 Use the RTO instruction to turn an output on or off after its timer has
been on for a preset time interval. The RTO instruction is a retentive
instruction that begins to count time base intervals when rung
conditions become true.

 The RTO instruction retains its accumulated value when any of the following
occurs:

 Rung conditions become false.

 You change processor operation from the

REM Run or REM Test mode to the REM

Program mode

 The processor loses power (provided that battery backup is maintained)

 A fault occurs

When you return the processor to the REM Run or REM Test mode and/or
rung conditions go true, timing continues from the retained accumulated
value. By retaining its accumulated value, retentive timers measure the
cumulative period during which rung conditions are true.

Figure 3.14.3

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 * COUNTERS

Counters are used to count the number of operations. Its function is same as
the timer accepts that the timer counts the number of seconds and the
counter counts the number of operations or pulses. At each operation the
value of the accumulator increases and when the value of the accumulator
comes to the preset value of the counter then the counter stops.

* COUNTER BITS:

 TT - Timer timing bit - This bit will be high during the counting
process. It remains high till accumulator value becomes equal to preset
value
 DN – Done – This bit will be high when the counting process is ended.
It set to high when the accumulator value becomes equal to preset
value.

* COUNTER UP (CTU)

The CTU is an instruction that counts false-to-true rung transitions. Rung

transitions can be caused by events occurring in the program (from internal
logic or by external field devices) such as parts traveling past a detector or
actuating a limit switch. When rung conditions for a CTU instruction have
made a false-to-true transition, the accumulated value is incremented by one
count, provided that the rung containing the CTU instruction is evaluated
between these transitions. The ability of the counter to detect false-to-true
transitions depends on the speed (frequency) of the incoming signal. The
accumulated value is retained when the rung conditions again become false.
The accumulated count is retained until cleared by a reset (RES) instruction
that has the same address as the counter reset.

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 * COUNTER DOWN (CTD)

The CTD is an instruction that counts false-to-true rung transitions. Rung

transitions can be caused by events occurring in the program such as parts
traveling past a detector or actuating a limit switch. When rung conditions
for a CTD instruction have made a false-to-true transition, the accumulated
value is decremented by one count, provided that the rung containing the
CTD instruction is evaluated between these transitions. The accumulated
counts are retained when the rung conditions again become false. The
accumulated count is retained until cleared by a reset (RES) instruction
that has the same address as the counter reset.

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 * COMMAND FOR COMPARISON
* EQU (EQUAL TO)

This input instruction is true when source A becomes equal to source B.

The EQU instruction compares two user specified values if values are
equal, it allows rung continuity. The rung goes true and output energies.

* GEQ (GREATER THAN EQUAL TO)

The instruction compares two values and will be high when the counted
value becomes equal to or greater than the fixed value and will energize
everything that is connected next to it.

* LEQ(LESS THAN EQUAL TO)

This instruction compares two values and will be high when the counted
value becomes equal to or less than the fixed value and will energize
everything that is connected next to it.

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 * GRT (GREATER THAN)

Use of the GRT instruction to test whether one value (source A) is greater
than another (source B). If the value at source A is greater than the value at
source B, the instruction is logically true. If the value at source A is less
than or equal to the value at source B, the instruction is logically false.
Source A must be an address. Source B can either be a program constant or
an address. Negative integers are stored in two’s complement form.

* LES (LESS THAN)

Use of the LES instruction is to test whether one value (source A) is less
than another (source B). If source A is less than the value at source B, the
instruction is logically true. If the value at source A is greater than or equal
to the value at source B, the instruction is logically false. Source A must be
an address. Source B can either be a program constant or an address.
Negative integers are stored in two’s complement form.

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 * LIM (LIMIT)

Figure 3.18.6

Use the LIM instruction to test for values within or outside a specified
range, depending on how you set the limits.

* RESET

Figure 3.18.7

Use a RES instruction to reset a timer or counter. When the RES instruction
is enabled, it resets the Timer ON Delay (TON), Retentive Timer (RTO),
Count UP (CTU), or Count down (CTD) instruction having the same
address as the RES instruction.

When resetting a counter, if the RES instruction is enabled and the counter
rung is enabled, the CU or CD bit is reset. If the counter preset value is
negative, the RES instruction sets the accumulated value to zero. This in
turn causes the done bit to be set by a count down or count up instruction.

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 1

* COMPARE PROGRAMMING

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CHAPTER: 3

SUPERVISORY CONTROL AND DATA ACQUISITION

* SCADA

SCADA (stands for supervisory control and data acquisition). It generally

refers to an industrial control system a computer system monitoring and controlling
a process. SCADA stands for Supervisory Control and Data Acquisition. As the
name indicates, it is not a full control system, but rather focuses on the supervisory
level. As such, it is a purely software package that is positioned on top of hardware
to which it is interfaced, in general via Programmable Logic Controllers (PLCs), or
other commercial hardware modules.

SCADA systems are used not only in industrial processes: e.g. steel making, power
generation (conventional and nuclear) and distribution, chemistry, but also in some
experimental facilities such as nuclear fusion. The size of such plants range from a
few1000 to several 10 thousands input/output (I/O) channels. However, SCADA
systems evolve rapidly and are now penetrating the market of plants with a number
of I/O Channels of several 100 K: we know of two cases of near to 1 M I/O
channels currently under development.

LEADING

SCADA
Invensys Wonder

ware: In touch

Siemens: Win

CAllen
Bradley:RSView32

Industrial process includes those of manufacturing production, power

generation, fabrication, and refining, and may run in continuous, batch,
repetitive, or discrete modes.

Infrastructure processes may be public or private, and include water

treatment and distribution, wastewater collection and treatment, oil an
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gaspipeline, electrical power transmission and distribution, and large

communication system.
Facility processes occur both in public facilities a private ones, including
building, airports, ships, and space station.

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* TYPES OF SCADA
1. D+R+N ( Development +Run + Networking)

2. R+N (Run +Networking)

3. Factory focus

* FEATURES OF SCADA
1. Dynamic process Graphic

2. Alarm summery

3. Alarm history

4. Real time trend

5. Historical time trend

6. Security (Application Security)

7. Data base connectivity

8. Device connectivity

9. Scripts

10. Recipe management

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* REAL-TIME AND HISTORICAL TRENDS

4. This facility is used for representing the data in graphical form.

5. Typically the trends plots the value with reference to the time.

6. Real-time data will plot the real-time value fixed period of

time whilehistorical data stored value which can be viewed on
demand.

7. Depending upon the storing capacity of the hard-disk on can

specify theno of days the data can be stored.

8. Some SCADA software show real-time and historical trends

in singlegraphics while few others use separate tools.

Figure 4.2.2

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* ALARMS

Every plant need proper monitoring and control of the process parameters.
Alarms represent warnings of process conditions that could cause problems,
and require an operator response

9. Generally alarms are implemented by using the lamps or hooters in

fieldbut in SCADA it can be represented using animation.

10.In many SCADA software, four type of alarm limits are used i.e.
HI, HIHI, LOW, LOW LOW.

Figure 4.2.3

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* RECIPE MANAGEMENT
11.In many case we use the same plant for manufacturing different
product range. For example an oil blending plant can manufacture
power oil, transformer oil, and automobile oil.

12.The recipe management is facility is used to 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

Figure 4.2.4

Figure 4.2.4

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* SECURITY

 Every SCADA Software has various levels of security for securing the
application by avoiding unauthorized access.

 Depending upon the access level given the operator / engineers is allowedto
do the task. In the most of the case, operators are allowed only to operate the
plant while maintenance engineers can do the application modification.

 The security can be given for individuals as well as for groups.

Figure 4.2.5

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* DEVICE CONNECTIVITY
13. Every Control hardware has its own communication protocol for
communicating with different hardware / software. Some of the leading
communication protocol include Modbus, Profibus, Ethernet, Dh+, DH 485,
Device net, and Control net.
14. The Scada Software needs device driver software for communication with PLC or
other control hardware.
15. More the driver software available better is the device connectivity. Mostof the
SCADA software used in the industry have connectivity with mostof the
leading control system.

* DATABASE CONNECTIVITY
16. In many plants, it is important to download the real-time information to
the Management information system. In this case the database
connectivity is must.
17. Many SCADA software don’t have their own database. Hence for storage
and reporting they use third party database like MS Access or SQL.

* SCRIPTS
18. Script is a way of writing logic in SCADA software, every SCADA soft-ware
has its own instruction and way of writing programed.
19. Use scripts, one can develop complex applications. You can create your own
functions to suit the requirement. Execution.
20. Various types of scripts make project execution simpler for programmer.

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* POTENTIAL BENEFITS OF SCADA

The benefits one can expect from adopting a SCADA system for the control
ofexperimental physics facilities can be summarized as follows:

1. The amount of specific development that needs to be performed by the

end- user is limited, especially with suitable engineering.

2. Reliability and robustness: These systems are used for mission critical
industrial processes where reliability and performance are paramount.In
addition, specific development is performed within a well-established
framework that enhances reliability and robustness.

3. Technical support and maintenance by the vendor.

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* APPLICATION OF SCADA
 Industrial automation
 Electric power generation, transmission and distribution.
 Water management
 Manufacturing

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* SCADA PROGRAMMING

The SCADA system used by us is SCADA Intouch Wonder. This SCADA system is
created by Wonder Ware. It has variety of commands, tool library and many other
features required for programming. It is an integrated, component-based software
for monitoring and controlling automation machines and processes.

 Open its graphic displays as OLE containers for ActiveX® controls —

with thousands of third-party ActiveX controls to choose from, you can
drop ready-made solutions right into your projects
 Develop an object model to expose portions of its core functionality,
allowing it to interoperate easily with other component-based software
products
 Support OPC standards as both a server and a client for fast, reliable
communications with a wide variety of hardware devices

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* PROGRAMMING WITH INTOUCH

 Double click on “in touch” icon and a window will appear named
in touch Application Manager’.
 Create a ‘New’ application.

 Then give a specific name to it.

Figure 4.8.1

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1. Now open that application.

2. A window is appeared as:-

Figure

3. Select windows properties and click OK

4. At the right most corner of this software the project window will appear. In this
window there are all the options related to our project in the SCADA. Like
system, graphics, alarms, buttons, data logs, logic & control etc.

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* RELAYS

A relay is an electrical switch that opens and closes under the control of another
electrical circuit. In the original form, the switch is operated by an electromagnet
to open or close one or many sets of contacts. It was invented by Joseph Henry
in 1835

Figure

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TECHNOLOGIC
CHAPTER 4

CONCLUSION

With the speed of changing technology today it is easy to lose sight or knowledge of the
basic theory or operation of programmable logic. Most people simply use the hardware to
produce the results they desire. Hopefully, this report has given the reader a deeper insight
into the inner workings of programmable logic and its role in mechanical operations.

The idea of programmable logic is very simple to understand, but it is the complex
programs that run in the ladder diagrams that make them difficult for the common user to
fully understand. Hopefully this has alleviated some of that confusion.

SCADA is used for the constructive working, using a SCADA system for control ensures
a common framework not only for the development of the specific applications but also
for operating the detectors. Operators experience the same “look and feel” whatever part
of the experiment they control. However, this aspect also depends to a significant extent on
proper engineering.

REFERENCE

 WWW.SOFCONTRAINING.COM
 WWW.INSTRUMENTENTION.IN /BASICPLCLADDERTRAINNING
 WWW.ACEDEMIA.IN
 HTTPS://WWW.RESEARCHGATE.NET

 A MANNUAL OF “ INDUSTRIAL AUTOMATION TAINING” BY

SOFCON GROUP

 TRAINING REPORT ON PLC SCADA AND AUTOMATION BY

VIKASH RAJAN (JAIPUR ENGINEERING COLLEGE)

 PLC & SCADA, a Case Study: -Autoclave Automation

 WWW.PLASMAINDUCTION.COM