PLC Scada Report
PLC Scada Report
In partial
fulfillment for the
award of the Degree
of
Bachelor of Technology
in
Electrical
Engineering
by
Vishal Supadu Mahajan
(2054491293020)
SESSION: 2022-23
CERTIFICATE
This is to certify that Vishal Supadu Mahajan studying in the VII semester
Electrical Engineering in the academic session 2022-23 of this college has completed
BTEEF711 Internship towards partial fulfillment of the requirement for the award of
degree in Electrical Engineering of the Dr. Babasaheb Ambedkar Technological
University, P.O Lonere, Dist. Raigad Maharashtra.
The work has been carried to our entire satisfaction and it is a bonafide
presentation of work done by them under the guidance and supervision.
The Internship report entitled “ The World of Automation in PLC and SCADA” Submitted
by Mr. Vishal Supadu Mahajan .
has been examined by the undersigned as a part of the examination and is hereby recommended
for the award of the degree of Bachelor of Technology in the faculty of Electrical Engineering
of Dr. Babasaheb Ambedkar Technological University, Lonere (M.S.) India.
ACKNOWLEDGEMENT
am also grateful to Dr. Namra Joshi, Mr. Gaurav Patil, Mr. Sandeep Ushkewar, Mr.
Jagdish More, Mrs. Farha Naaz, Mr. Shahid Akhtar, Mr. T M Shubham and Mr.
Ankush Mudholkar Assistant Professor, Department of Electrical Engineering for their
valuable help and guidance ,sharing expertise and sincere encouragement extended to
me.
I would also give my sincere thanks to principal Dr. Nilesh P Salunke, for giving
me an opportunity to do my degree in this reputed college.
Table of Contents
Abstract ⅲ
List of Tables ⅳ
List of Figures ⅴ
List of Abbreviations ⅵ
5. Certificate 19
6. References 20
Motivation
The is 21st century challenge vendors who are still promoting product “features” or
“benefits” to a world that is only interested in results, will not stay in business and
manufacturers who are just chasing new technology, will never complete in global
marketplace. The automation industry users and suppliers needs to strike the right balance
between technology innovation and marketing process improvement.
Over the past years, there has been a positive growth in the global industrial
automation industry. According to a report, industrial automation market is expected
to reach 153.83 Billion Dollars by 2022, growing at 5.10% between 2017 and 2022.
Moreover, usage of automation techniques is on the rise and is expected to continue
rising for the foreseeable future.
These expectations showcase that global industrial automation companies are preferring
automation to reduce manual labor inputs and decrease costs. It further eliminates the
requirement for many low-paying offshore jobs and allows the companies to increase
the need for high-skilled activities.
The industrial world is facing many technological changes which increased the urgent
demand for the premium quality products and services that can only be supplied by
a high level of productivity. This requirement needs process engineering systems,
automated manufacturing, and industrial automation. Hence, industrial automation plays
a key role in solving the requirements of companies. It is extremely significant to
face the tasks
On the other hand, industrial automation is all about working smarter, faster, and proficiently.
This makes automation more powerful and that’s why customers are looking for pioneering,
end-to-end technologies with open, modern architecture and new data from new connections.
As the industrial automation industry comprehends the advantages of the Internet of Things
(IoT), it is becoming essential that organizations adopt these technologies.
Industrial automation refers the categorization of software and hardware and a mechanism
that combines them hardware & software. Moreover, it involves the process of rolling out
new features using advanced technology in business to reduce limitations. Automation can be
achieved by installing automated devices or embedded systems as well as automation
software performing the logical tasks and control the operation processes.
Implementation of these devices, software, and hardware will be the ‘Solution’ to deliver the
operation to be automated. These solutions are widely used nowadays to enhance efficiency
and productivity of businesses.
Automation has been using everywhere nowadays. PLC, SCADA, DCS, Process Instruments
etc. have made automation more reliable and powerful.
Abstract
iii
List of Tables
1 Week-1 1
2 Week-2 4
iv
List of Figure
5 Latching concept 12
List of Abbreviations
ADD Addition 2
SUB Subtract 3
MUL Multiply 4
DIV Divide 5
Vi
Table 1. Week 1
1. Week-1
Automated iManufacturing:
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 advantage 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.
ii
Home iAutomation:
Home automation designated 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 iAutomation:
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 application for example found in motor controls, general
purpose pumps, fans and e-bikes to reduce energy consumption and thus increases efficiency.
2. WEEK-2
Table 2 Week-2
Addressing concept,
11/8/2022 8 am to 12 pm Implementation of logic
gates,
Latching concept and Holding concept.
Timer concept and Program on timer
12/8/2022 8 am to 12 pm Counter concept and programming ON counter
PLCs were initially designed to replace electromechanical relay systems in order to offer a
simpler solution for modifying the operation of a control system. Rather than having to
rewire a large bank of relays, a quick download from a PC or programming devices enables
changes to the control logic in a matter of seconds.
PLC has become the most popular instrument for industries to control different processes that
is performing in the industry. It is an industry type computer that is programmable for
controlling functions. Due to its programmable capability wiring control system been
removed from industries like relays controlling. The main advantage is its programming
language is very simple there is no need to use specific tools like other computer languages
such as C, C++, etc.
Advantages of PLC:
1. They are user friendly and easy to operate.
2. They eliminate the need for hard-wired relay logic.
3. They are fast.
4. It is suitable for automation in industries.
5. Its input and output modules can be extended depending upon the requirements.
PLC System
Input/ Output Section: The input section or input module consists of devices like sensors,
switches, and many other real-world input sources. The input from the sources is connected
to the PLC through the input connector rails. The output section or output module can be a
motor or a solenoid or a lamp or a heater, whose functioning is controlled by varying the
input signals.
CPU or Central Processing Unit: It is the brain of the PLC. It can be a hexagonal or an octal
microprocessor. It carries out all the processing related to the input signals in order to control
the output signals based on the control program.
Programming Device: It is the platform where the program or the control logic is written. It
can be a handheld device or a laptop or a computer itself.
Power Supply: It generally works on a power supply of about 24 V, used to power input and
output devices.
Memory: The memory is divided into two parts, the data memory and the program memory.
The program information or the control logic is stored in the user memory or the program
memory from where the CPU fetches the program instructions. The input and output signals
and the timer and counter signals are stored in the input and output external image memory
respectively.
1. NOT Gate
2. AND Gate
3. OR Gate
4. NAND Gate
5. NOR Gate
Working: NOT gate works as inversion. It takes one input and gives one output.
When the input is high then the output is low and vice-versa.
NOT Gate in PLC programming: In the case of PLC ladder, there will be a push
button to provide input. When (I1) is pressed then the coil (Q1) is on. And when Input
(I1) is released then coil Q1 is off.
Symbolic Representation:
2. AND Gate
Working: In AND Gate, when both inputs (I1 and I2) are high then the output (Q1)
will be high. For all other inputs, output (Q1) will be the low.
0 0 0
0 1 0
1 0 0
1 1 1
Using Ladder diagram programming, we are connecting two switches (I1 and I2) as input
and coil/lamp (Q1) as output. In the case of both switches (I1 and I2) are closed, the lamp
(Q1) will glow. In another case, if any of the switches (I1 or I2) are open then lamp (Q1)
will not glow.
Symbolic Representation:
3. OR Gate
Working: If both inputs are low in the OR gate, then the output will be low. For all
other cases, the output will be high.
0 0 0
0 1 1
0 1 0
1 1 1
OR Gate in PLC programming: In case both or anyone inputs (I1 and I2) are
closed then coil (Q1) will on.
Symbolic Representation:
In the above circuit diagram, switch (I1) is pressed then the coil (Q1) will be energized.
After releasing switch (I1), the energizing coil (Q1) is providing supply to switch (I2). Then
switch (I2) will become automatically activated.
As soon as start push button is pressed, the contact I0.0 (N-O) becomes N-C. As the N-
O contact I0.1 is already becomes the N-C (because of the normally closed push button
in physical connections), the rung goes true and the coil (bulb) Q0.0 becomes energized.
Now, if the start push button is released then also the bulb will remain ON (here
comes the concept of latching.
As soon as the coil Q0.0 gets energized, the latched contact of this coil which is represented
as Q0.0 (N-O) becomes N-C and the logic will pass through this rung and remains the bulb
ON even if the start push button is released. If we want to switch OFF the bulb ,we simply
have to press the stop push button .Due to pressing of stop push button the contact I0.1
becomes N-O (normally open) and rung logic goes false, which in turn de-energizes the coil
Q0.0 and switches OFF the bulb.
Take for instance this PLC program, designed to sound an audio alarm siren prior to starting a
conveyor belt. To start the conveyor belt motor, the operator must press and hold the “Start”
push-button for 10 seconds, during which time the siren sounds, warning people to clear
away from the conveyor belt that is about to start. Only after this 10-second start delay does
the motor actually start and latch “on”:
Similar to an “up” counter, the on-delay timer’s elapsed time value increments once
per second until the preset time (PT) is reached, at which time its output (Q) activates.
In this program, the preset time value is 10 seconds, which means the Q output will
not activate until the “Start” switch has been depressed for 10 seconds. The alarm siren
output, which is not activated by the timer, energizes immediately when the “Start” push-
button is pressed.
PLC counters are internal PLC instructions that can be used to count input or output
signals in the PLC program. These counters operate like relay counters but you
cannot hold a PLC counter in your hand and they do not need to be connected to
wires to operate.
Types of PLCcounters
There are two main types of PLC counters, the count-up counter, and the count-down
counter.For the counter-up counters, we have a counter file name, a counter preset
value, a counter accumulated value, a counter count-up bit, and a counter done bit.
For the counter-down counters, we have the same bits and values. The only thing
that is different is the counter-down bit on the output. As you can see below, we
have this as counter-up bit for the counter-up counter.
1. Addition (ADD):
Use the ADD instruction to add one value (source A) to another value (source B) and place
the result in the destination.
2. Subtract (SUB):
Use the SUB instruction to subtract one value source B from another source A and place the
result in the destination.
3. Multiply (MUL):
Use the MUL instruction to multiply one value source A by another source B and place the
result in the destination.
4. Divide (DIV):
Use the DIV instruction to divide one value source A by another source B. The rounded
quotient is then placed in the destination. If the remainder is 0.5 or greater, round up occurs
in the destination. The unrounded quotient is stored in the most significant word of the math
register. The remainder is placed in the least significant word of the math register.
When this instruction is evaluated as true, the square root of the absolute value of the source
is calculated and the rounded result is placed in the destination. The instruction calculates the
square root of a negative number without overflow or faults. In applications where the source
value may be negative, use a comparison instruction to evaluate the source value to
determine if the destination may be invalid.
Use the SCP instruction to produce a scaled output value that has a linear relationship
between the input and scaled values. This instruction supports integer and floating point
values. Use this instruction with SLC 5/03 (OS302), SLC 5/04 (OS401), and SLC 5/05
processors
units: y = mx + b
Where:
y = scaled output
The Ramp (RMP) instruction provides the ability to create linear, acceleration, deceleration,
and “S” curve ramp output data wave forms. This instruction provides a means to ramp
analog outputs when using them to control devices such as valves.
NEQ Not equal Test weather one value is not equal to second value.
LEC Less than Test weather one value is less than second value.
LEQ Less than or Test weather one value is less than or equal to second value
equal
GRT Greater than Test weather one value is greater than another
GEQ Greater than Test weather one value is greater than or equal to
or equal second value
MEQ Masked Test portion of two values to see weather they are equal.
comparison for Compares data through the mask.
equal
LIM Limit test Test weather one value is within the limit range of two
other values
Comparison instructions in PLC are used to test pairs of values to condition the
logical continuity of a rung.
As an example, suppose a LES instruction is presented with two values. If the first
value is less than the second, then the comparison instruction is true.
The data comparison instruction gets the PLC to compare two data values. Thus it
might be to compare a digital value read from some input device with a second value
contained in a register.
3. Social Impact
4. Outcomes of Internship
5. Certification