Training report 2012 2015-sonu yadav

INDUSTRIAL TRAINING REPORT
Page 1
ON
“INDUSTRIAL AUTOMATION”
Submitted in partial fulfillment of the
Requirements for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
Electronics’ & Communication Engineering.
(Session 2012-2015)
Submitted By:
Sonu Yadav
Roll. No: 2557005
Under the Guidance of
Mr. Sandeep
(H.O.D E.C.E)
Department of Electronics’ & Communication Engineering
YADUVANSHI COLLEGE OF ENGINEERING & TECHNOLOGY
Narnaul Rewari Road, Patikra, Narnaul-123001(Haryana)

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DECLARATION
I hereby declare that the Industrial Training Report done at “Digilog Automation Pvt. Ltd.” is
an authentic record of my own work as requirements of 6-months Industrial Training during the
period from January 2015 to July 2015 for the award of degree of B.Tech. (Electronics &
Communication Engineering), Yaduvanshi College of Engineering & Technology, Narnaul,
Mahendergarh, under the guidance of Mr. Sandeep (H.O.D E.C.E Dep’t)
Sonu Yadav
2557005
Date: ____________________
Certified that the above statement made by the student is correct to the best of our knowledge and belief.
Signatures
Examined by:
1. 2.
3. 4.
Head of Department
(Signature and Seal)

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CERTIFICATE
This training report is a genuine works by Mr. Sonu Yadav, B.Tech final yr, from Yaduvanshi
College of Engineering & Technology. The report was made under my supervision, and I express
my delight on it Successful completion. I also very happy to have offered her guidance whenever it
was required.
I wish her successful in all her future endeavors.
Mr. Sandeep Kumar Sonu Yadav
(H.O.D E.C.E Dep’t.) 2557005
E.C.E (8th
SEM)

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ACKNOWLEDGMENT
I am thankful to the “Digilog Automation Pvt. Ltd” for providing
necessary facility to carry out my training successfully. I’d also like to
thank Er. Arun sing(M.E) and Er. Sunil Kumar (E.E), for enduring support
and guidance throughout the training I am very grateful to the whole
control and instrumentation Department for their support and guidance.
Also, I am highly obliged to the head of our training and placement cell
that provided me such a great opportunity to do my summer training in a
reputed institute like.
Digilog Automation Pvt. Ltd
ISO 9001-2008 Certified Company…
Sonu Yadav
2557005
E.C.E 8th
Sem.

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PREFACE
It gives me an immense pleasure to submit this report as a part of practical training of 6 Months
Practical training is the most important part of the engineering studies.
During the course of the training a trainee learns to correlate both the practical problem to the
possible theoretical knowledge or solution .This training record is prepared on the basis of my
own experience gained during my practical training. On the basis of information collected and
guidance provide I had prepared a comprehensive training report. This report contain the history,
Introduction, quality policy and description op PLC, SCADA, HMI, instrumentations
Sonu Yadav
E.C.E 8th
Sem.
2557005

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Table of Content
S.No Particulars Page No.
1. Abbreviation 7
2. Training Establishment Page
3. Automation
Introduction 8
Example of automation 8 to 9
Types of automation, industrial automation 10-15
4. Programmable logic controller PLC
Introduction, Relay 16
History of PLC, Advantages 17 to 19
Inside PLC, CPU, RAM, ROM, EEPROM, I/P Module 20 to 21
Output Module. Sensor, Actuator 22 to 24
Number system, decimal, binary 25 to 26
Converting binary to decimal, Bits, byte words.logic1, logic0 27 to 29
BCD, Hexadecimal, communication 31 to 32
PLC operation, Programming PLC, Ladder logic, Example 33-37
5. SCADA 38-44
Introduction 38
System concept 39
Tags, types of Tags, classification of tags 40 to 41
Alarm, System components, Salient features 42 to 43
Benefits SCADA/HMI, Recommend 44
6. HMI
Introduction, types, difference between 45 to 47
7. Instrumentation, Application of automation, plc SCADA 48 to 49
8. Conclusion 50
9. References 51
10. Bibliography 52

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General Abbreviation
PLC: Programmable logic controllers.
SCADA: Supervisory control and data acquisition.
I/P: Input
O/P: Output.
T-On: On timer.
T-Off: Off timer.
M: Memory Bits.
Q: Output in program.
MW: Memory words.
NO: Normally open.
NC: Normally closed.
DCS: Distributed Control System.
HMI: Human machine interference.
VFD: Variable Frequency Drive.
MD: Memory Double Word.
MB: Memory Byte
XIC: Examine If Closed
XIO: Examine If Open

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TRAINING ESTABLISHMENT
Digilog Automation Pvt. Ltd.
Digilog Automation Pvt Ltd., , a part of Digilog Group, has been an integral part of the industrial
automation fraternity since 1989. The company is engaged in providing Sales and Services for
reputed manufacturers of automation products and its range of industrial products.
Digilog Automation Pvt Ltd offers automation consultancy for an entire spectrum of machinery
and industrial processes, fulfilling the growing expectations of customers. The sequence of
operations at the company includes a detailed study of customers’ applications, developing
comprehensive solutions followed by the proper commissioning of the automation systems.
Our success can be attributed to the incorporation of the innovative technologies in our
functioning. This includes being abreast with the latest advancement in PLC, PC, VFD, Servo
drives based motion control systems, SCADA systems and custom built PC software as applicable
to factory automation needs.
We have successfully completed more than 3000 projects for different customers.
Services offered:
Programmable Logic Controllers ( PLC)
Variable Frequency Drives ( VFD)
Servo Drives
Operator Terminals ( HMI)
SCADA projects

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Control/Operator Panels
Motion Control Systems
Control and Power Panels
Industrial Computers
Training Programs.
Electronics for Robotics and Multi-axis controllers
Electrical Outsourcing and Reconditioning
Energy Conservation Projects.
Digilog team
With Digilog Automation Pvt. Ltd., , you benefit from a team of proven expertise in factory
automation solutions. Our engineers have successfully implemented machine control systems
converting brilliant design ideas into feasible realities for customers. Our programmers , specially
trained in new technologies have completed projects in diverse automation using products as
mentioned above.
Combine these quality of human resources with state-of the art infrastructure for a compete picture
of Digilog Automation Pvt. Ltd . Standing on this edifice, the company is poised to scale greater
heights of quality and innovation in its endeavor for customer satisfaction.
Over a period of several years Digilog has successfully commissioned and maintained over 300
systems in the region. This speaks about or promises and commitment to offer round the clock
service to each of our customers.
Application and Customer Domain
 Pharmaceuticals

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 Machine Tools
 Material Handling
 Packaging
 Plastics
 Vaccum
 Process Control.
 Rubber
 Utility
 Welding
 Plastics , Pipes moulding
 Automatic Test Equipments
 Chemicals.,
 Conveyors
Esteemed Clients
 Motor Industries Co Ltd.,
 Perfect Circle India Ltd.,
 Gabriel India Ltd.,
 Mahindra and Mahindra Igatpuri
 Mahindra and Mahindra Nagpur
 Bosch Chasis., Jalgaon
 Supreme Plastics Ltd , Jalgaon
 Precise Vaccum Pvt Lt.d,
 Atlas Copco Ltd.,
 Chemito Industries Ltd.,
 Orbital Systems Ltd.,

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 Graphite Vicarb India Ltd.,
 Kiroskar Oil Engines Ltd.,
 Veeraja Industries.
Contact Address
Digilog Automation Pvt. Ltd.,
4- A, Priyanka Pride .,
Near Water Tank., Mahatmanagar.,
Nashik 422007
Phone :+91-253- 6610070
Mail : kmv@digilog.co.in
Web : www.digilog.co.in

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Chapter: 1
AUTOMATION
Introduction
Automation is the use of control system such as computers to control industrial machinery &
process, reducing for need for human intervention. In the scope of industrialization,
Automation is a step beyond mechanization. Whereas mechanization provided human operators
with machinery assist them with physical requirement of work, automation greatly reduces the
need for human sensory and mental requirements as well. Process and system can also be
automated.
In other words
Automation is a delegation of human control function to technical equipment for increasing productivity, to
better quality, to reduce cost & increase in safety working condition, to reduce manpower.
Example of automation
a) Automatic machine tools to process parts- CNC m/c
b) Industrial robots
c) Automatic material handling
d) Feedback control system

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EXAMPLE OF AUTOMATION
Automatic Material Handling Conveyors.
Industrial Robots

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feedback control systems
TYPES OF AUTOMATION
1) Fixed automaton
2) Programmable automation
3) Flexible automation
Fixed automation
Fixed automation refers to the use of custom-engineered (special purpose) equipment to
automate a fixed sequence of processing or assembly operations. This is also called hard
automation.
The primary drawbacks are the large initial investment in requirement and the relative
flexibility.

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Programmable automation
In programmable automation, the equipment is designed to accommodate a specific class of
product changes and the processing or assembly operation can be changed by modifying the
control program.
Flexible automation
In flexible automation, the equipment is designed to manufacture a variety of products or
parts and very little time is spend on changing from one product to another . A flexible
manufactures various combinations of products according to any specified schedule.
INDUSTRIAL AUTOMATION
Field instrument
This type of instrument mainly used to get the feedback any type of process carried our so
they mainly use:
1. Sensors,
2. Transducer and
3. Transmitter
PLANT
Monitoring &
controller
Field
instrument
Intelligent
controller

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Proximity Sensor.
Intelligent controller
This device is basically micro control based or micro controller device mainly intelligent
controllers are:
i. Programmable logic controller (PLC)
ii. PID Controller
iii. Distributed controller system (DCS)
iv. Computer Numerical controller (CNC

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PLC
PID

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CNC MACHINE
Monitoring and controller
This type of device to control whole plant just in a setting in control room, so mainly control
device are
 Supervisory Control & Data Acquisition (SCADA)
 Human Machine interface (HMI)

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600 Series touch screen HMI.

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Chapter: 2
PROGRAMMABLE LOGIC CONROLLER
Introduction
A PLC is a solid device designed to perform the function previously accomplished by
components such as electromechanical relay, drums switch, mechanical timers /counter etc.
for the control and operation of manufacturing process equipment and machinery. Even
thought the electromechanical relay (control relay, pneumatic timer relay, etc) have served
well for many generations, often under adverse conditions, the
ever increasing sophistication and complexity of modern processing equipment requires
faster acting, more reliable functions that electromechanical relays or timing devices can’t
offer.
What is relay?
A relay is an electromechanical switch, operated by passing current through a coil wire wound
around a steel core, which act as an electromagnet pulling the switch contact down or break a
circuit
Figure:Relay
HISTORY OF PLC
 The first programmable logic controller were designed and developed by Modicon as
a relay replacer for GM and Landis.

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 This controller eliminated the need for rewiring and adding additional for each new
configuration of logics.
 The new system drastically increased the functionality of the control while reducing
the cabinet space that housed the logic.
 The first PLC, model 084, was invented by Dick Morley in 1969.
 The first commercial successful PLC, the 184, was introduced in 1973 and was
designed Michael Greenberg.
ADVANTAGES
PLC not only capable of performing the same tasks as hard-wired control, but are also capable of many
more flexible application. In addition, the PLC program and electronic communication lines replace much
of the interconnecting wires require hardwire control. Therefore, hard wiring, thought still required to
connect field device, is less intensive. This also makes correcting errors and modified the application
easier.
Some of the additional advantages of PLCs are as follow
 Smaller physical size than hard-wire solutions
 Easier and faster and to make changes.
 PLCs have integrated diagnostics and override functions
 Diagnostics are centrally available

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 Application can be immediately documented
 Application can be duplicated faster and less expansively
 Speed in operation
 Security
 Online/ offline modifications
Photograph showing several input and output modules of a single
Allen-Bradley PLC.
INSIDE PLC
The Central processing Unit (CPU), contains and internal program that tells the PLCs how to
perform the following functions:
 Execute the control instructions contained in the user’s Programs. This program is store in
“nonvolatile” memory,
Meaning that the program will not be lost if power is removed.
 Communicate with other device, which can include I/O Device, programming device,
networks and even other PLCs
 Performs housekeeping activities such as communication, internal diagnostic, etc.

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THE CPU
The microprocessor or processor module is the brain of PLC system. It consists of the
microprocessors, memory integrate circuits, and circuits necessary to store and retrieve
information from memory. It also includes communication ports to the other peripherals, other
PLCs or programming terminals. Today’s processors vary widely in their capabilities to control the
real world devices. Some control as few as 6 inputs and outputs (I/O) and other 40,000 or more.
One processor can be control more than one process or manufacturing line. Processors are often
linked together in order to provide continuity throughout the process.
RAM
RAM or Random Access Memory is a volatile memory that would lose its information if power were
removed. This is why some processors units incorporate a battery back-up. This type of RAM normally
used CMOS or Complementary Metal Oxide Semiconductor. CMOS RAM is used for storage of the user’s
program (ladder logic diagrams) and storage memory.

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ROM
ROM or Read only memory is a non volatile memory. This means you don’t need external power source to
keep information. In this type of memory, information can be read, but not changed. For these reason the
manufacture sometimes calls this firmware. It is placed their for the internal use and operation of
processors units.
EEPROM
EEPROM or Electrically Erasable programmable Read Only Memory is usually an add-on
memory module that is used to back of the main program in COSMOS RAM of the processors.
Can be programmed to load the EEPROM’s program to RAM is lost or corrected.
INPUT MODULE
There are many types of input module to choose form. These type of module used is dependent
upon what real world input to the PLCs is desired. Some example input is limit switches, electric
eyes, and pushbuttons. DC input, such as thumbwheels switches, can be used to enter integer
values to the manipulated by the PLC, DC input cards are used for this application. Since most
industrial power systems are inherently noisy, electrical isolation is provided between the input and
the processor. Electromechanical interference (EMI) and radio frequency interference (RF) can be
cause severe problems in most solid state control systems. The component used most often to
provide electrical isolation within I/O cards is called an optical isolator. The wiring of an input is
not complex. The object is to get a voltage at a particular point on the card. Typically there are 8 to
32 input points on any one input module. Each point will be assigned a unique address by the
processor. Analog input modules are special cards that use analog to digital conversion (A to D) to
sense variables such as temperature, speed, pressure and position. The external device normally is

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connect to a controller (transducer) producing an electrical signal the analog input card can
interpret. This signal is usually 4 to 20 Ma or 0 to 10 volts.
OUTPUT MODULE
Output modules can be used for ac or dc devices such as solenoids, relay, contractor, pilot lamps,
and LED readouts. Output card usually have from 6 to 32 outputs on a signal module. The output
device within the cards provides the connection from the user power supply to the load. Usually
silicon controlled rectifier (SCR), triac, or dry contact relay are use for this purpose. Individual

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output are rated most often at 2 to 3 amperes. Output cards, like input cards have electrical
isolation between the load being connected and the PLC. Analog output cards are a special type
of output modules that use digital to analog conversion (D to A). The analog output module can
be take a value store in a 12 bit file and convert it to an analog signal. Normally this signal is 0-10
volts dc or 4 to 20 Ma. This analog signal is often used in equipment such as motor operated
valves and pneumatic position control device.
SENSORS
A sensor is a device that converts a physical condition into an electrical signal for use by the PLC. Sensors
are connected are input of a PLC. A pushbutton is one example of sensors that is connected to the PLC input.
An electrical signal is sent from the pushbutton to the PLC indicating the condition (open/closed) of the push
button contacts.
Pushbutton (Sensors)
ACTUATOR
Actuators convert an electrical signal from the PLCs into a physical condition. Actuators are connected to
the PLC output. A motor starter is one example of actuator that is connected to the PLC output. Depending
on the PLC signal the motor starter will either start or stop motor.
PLC INPUT
Actuator (Starter)
Motor
PLC INPUT

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NUMBER SYSTEM
Since PLCs is computer it stores information in the form of on or off conditions (1 to 0), refers to
as binary digits (bits). Sometimes binary digits are used individually and sometimes they are used
to represent numerical valves.
DECIMAL SYSTEM
Various number system are used by PLCs. All number systems have the same three characteristic:
 Digits
 Base
 Weight.
The decimal system, which is commonly used in everyday life, has the following characteristic:
Ten digits 0,1,2,3,4,5,6,7,8,9
Base 10
Weights 1, 10, 100, 1000……
BINARY SYSTEM
The binary system is used by programmable controllers. The binary system has the following
characteristic:
Two digits 0,1
Base 2

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Weights power of base 2 (1, 2, 4, 8, 1, 6……)
In the binary system 1s 0s are arranged into columns. Each column is weights. The first column
has a binary weight of 2.
This is equivalent to decimal 1. This is referred to as the least significant bit. The binary weight is
double with each succeeding column. The next column, for example, has a weight of 2^1which is
equivalent to decimal 2. The decimal value is double in each successive column. The number in
the far left hand column is referred to as the most significant bit. In this example, the most
significant bit has a binary weight of 2^7. This is equivalent to decimal to 128.
CONVERTING BINARY TO DECIMAL
The following steps can be used to interpret a decimal number from a binary value.
1. Search from least to most significant bit for 1s .
2. Write done the decimal representation of each column containing a 1.
3. Add the columns values.

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In the following example, the fourth and fifth columns from the right containing a 1.The decimal
values of the fourth column from the right is 8, and the decimal value of the fifth column from the
right is 16. The decimal equivalent of this binary number is 24. The sum of all the weighted
columns that contains a 1is the decimal number that the PLC has stored
BITS, BYTES, AND WORDS
Each binary piece of data is a bit. Eight bits make of one byte.
Two bytes, or 16 bits, make of one word.

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LOGIC 1, LOGIC 0
Programmable controllers can only understand a single that that is on or off (present or not
present).the binary system is a system in which there are only two numbers, 1 and 0.
Binary 1 indicates that a signal is present, or the switch is on.
Binary 0 indicates that a signal is present, or the switch is off.
BCD (Binary-coded decimal)
Binary-coded decimal (BCD) are the decimal number where the each digit is represented by a
four-bit binary number. BCD is commonly used with input and output devices. Thumbwheel stitch
is one example of an input device that uses BCD. The binary number is broken into group of four
bits, each group representing decimal equivalent. A four-digit thumb wheel switch, like the one
show here, would control 16 (4*4) PLC inputs.

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22
HEXADECIMAL
Hexadecimal is another system used in PLCs. The hexadecimal has the following characteristic:
16 digits 0,1,2 ,3,4,5,6,7,8,9,A,B,C,D,E,F
Base 16, weights power of base 16(16, 256, 4096…..)
The ten digits of the decimal system are used for the first ten digits of the hexadecimal system. The
first six letter of the alphabet are used for the remaining six digits.
A=10, B=11, C=12, D=13, E=14, F=15
The hexadecimal system used in PLCs because it allows the statues of large number of binary bits
to the represented in a small space such as on a computer screen or programming device display.
Each hexadecimal digit represented the exact of the four binary bits. To convert a decimal number
to a hexadecimal number the decimal number is divided by the base of 16.

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To convert decimal 28, for example, to hexadecimal
Decimal 28 divided by 16 is 1 with a remainder 12. Twelve is equivalent to C in hexadecimal. The
hexadecimal equivalent of decimal 28 is 1c.
The decimal value of a hexadecimal is obtained by multiplying the individual hexadecimal digits
by the base 16 weight and the adding the results. In the following example the hexadecimal
number 2B is converted to its decimal equivalent of 43.
23
COMUNICATION
There are several methods to communicate between a PLC and programmer or even between two
PLCs. Communications between a PLC and a programmer (PC or Hand held) are provided by the
makers and you only have to plug in a cable from your PC to the programming port on the PLC.
The communication can be RS232, RS485 or TTY. Communication between two PLCs can be
carried out by dedicated links supplied/ programmed by the makers (RS232 etc) or via outputs
from one PLC to the input on another PLC. The direct link method of communication can be as a

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simple as, if an output on the PLC is on then the corresponding input on the second PLC will be on
and then this input is used within on the program on the second PLC
PLC OPERATION
There are four basic steps in the operation of all PLCs. Which continually take place in a repeating
loop.
 Input scan
 Program scan
 Output scan
 Housekeeping
Input Scan
Detect the state of all input device that are connect to the PLCs.

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Program Scan
Execute the user create program logic.
OUTPUT SCAN
Energize or de-energize all output devices that are connect to the PLCs.
HOUSEKEEPING
This step includes communication with program terminals, internal diagnostic etc.
CHECK INPUT STATES
First the PLC takes a look at each input to determine if is on or off. In other words, is the sensors connected
to the first input on? Then second input? Then the third so on…it records this data into its memory to be
used during the next step.
EXECUTE PROGRAM
Next PLC executes your program one instruction at a time.
Maybe the program says that if the first input was on then it should on the first output. Since it is already
knows which input are on/off from the previous step it will be able to decide whether the first output should
be turn on based on state of first input. It will store the execution result for use during the next step.
UPDATE OUTPUT STATES
Finally the PLC updates the state of the outputs. It update the outputs base on which inputs were
on during the first step and the result of executing your program during the second step. Based on
the example of step 2 it would now turn on the first output because the first input was on and your
program said to turn on the first output when this condition is true.

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After the third step the PLC goes back to step one and repeats the step continuously. One scan time
is defined as the time is takes to execute the 3 steps listed below.
PROGRAMMING PLC
Various languages are used for programming of PLCs.
Ladder Diagram ( LD)
Ladder diagram is a graphic programming language derived from the circuit diagram of directly
wired relay control. The ladder diagram contains contact rails to the left the right of the diagram,
these contact rails are connected to switching elements (normally open/ normally closed contacts)
via current path and the coil elements.
FUNCTION BLOCK DIAGRAM (FBD)

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In the function block diagram, the function and blocks are represented graphically interconnected
into networks. The function block diagram originates from the logic diagram for the design of
electric circuits.
SEQUENTIAL FUNCTION CHART (SFC)
The sequential function chart is language resource for the structuring of sequence- oriented control
programs. The element of the sequential function charts are steps, transition, alternative and
parallel branching. Each step represents a processing state of a control program, which is active or
inactive. A step consists of action which identical to the transition, are formulated in the IEC 1131-
3 languages. Action themselves can again contain sequence structure. The feature permits the
hierarchical structure of the control program. The sequential Function Chart therefore an excellent
tool for the design and structuring of control programs.
LADDER LOGIC
Ladder Logic, Ladder programs is the most common programming language used to program a
PLC.

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Ladder Logic was one of the first programming approaches used in PLCs because it borrowed
heavily from the relay diagram that plant electricians already knew.
The symbols used in relay ladder Logic consists of a power rail to the left, a second power rail to
the right. The logic of each circuit (or rung) is solved to the left to right. The symbols of these
diagram look like a ladder with two side rails and circuits that resemble rungs on ladder.
The picture above represented single “rung” of ladder
 If input is on (or true)- power (logic) completes the circuits from the left rail- and output
turns ON(or true)
 If output is off (or false)- then the circuit is not complete and logic does not follow to the
right- and output 1 is OFF
There are many logic symbols available in ladder logic-includes
Timers , counter , Math, and Data moves such that any logical condition or control loop can
be represented in ladder Logic. With just hand full of basics symbols – a normally open
contact, normally closed contact, normally open coli, normally close coils, timer, counter
most logical conditions can be represented.
CONTACT AND COILS
With just the normally open contact and normal open coil a surprising array of basic logical conditions can
be represented.
Normally open contact
This can be used to represent any input to the control logic- a switch or sensor, a contact from an output, or
an internal output.

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When “solved” the reference input is examined for an ON (Logic1) condition. if it is ON, contact will
closed and allow power (logic) to flow from left to right. If the state is off (logic 0).then contact is open,
power (logic) will NOT from left to right.
Normally open coil
This can be used to represent any discrete output from the control logic
When “solve” if the logic to left of the coil is TRUE, the referenced OUT is ON (logic1)
SOLVING SINGLE RUNG
Suppose a switch is wired to input, and a light bulb is wired through output 1 in a such way that the
light is OFF when output1 is off and ON when output1is ON.
When input1 is OFF (logic 0) the contact remaining open and power can’t flow from left to right,
therefore,Output1 remain off (logic 0)
When input is ON (logic 1) then the contact close, power flows from left to right, and output1
becomes ON (the right turns ON)

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THE AND RUNG
The AND is a basic fundamental logic condition that is easy to directly represent in Ladder Logic.
Suppose a switch is wired to Switch1, a second switch is wired toSwitch2, and a light bulb is wired
through Light1 in such a way that the light is OFF when Light1 is OFF, and ON when Light1 is
ON.
InorderforLight1toturnON,Switch1mustbeON,ANDSwitch2mustbeON.
If Switch1 is OFF, power (logic) flow from the left rail, but stops at Switch1. Light1 will be OFF
regardless of thestateofSwitch2.
If Switch1 is ON, power makes it to Switch2. If Switch2 is OFF, power cannot flow any further to
the right, andLight1isOFF.
IfSwitch1isON,ANDSwitch2isON-powerflowstoLight1solvingitsstatetoON.
THEORRUNG
TheORisalogicalthatiseasytorepresentinladderdiagram

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Supposeaswitchiswiredtoswitch1,secondswitchiswiredtoswitch2,andthelightbulbiswiredthroughalight1in
suchawaythelightisOFFwhenlightisOFF,andONwhenlightisON.Inthisinstance,wewanttothelighttoturn
ONifeitherswitch1ORswitchisON.
Ifswitch1isON-powerflowtoLight1turningitON.
Ifswitch2turnisON–powerflowsthroughtheswitch2contact,anduptherailtolight1-turningitON.
Ifswitch1ANDSwitch2areON-light1isON.
TheonlywayLight1isOFFisifSwitch1ANDSwitch2areOFF.
MOTOR STARTER EXAMPLE:

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Firstconsiderahardwiredapproach
The following line diagram illustrate how a normallyopen and a normallyclosed pushbutton might be connected to
controlathree-phaseACmotorasshownabovefigure.
In this example , a motor starter coil (M) is wired in series with a normally open, momentary start pushbutton, a
normallyclosed,momentary stoppushbutton,andnormallyclosedoverloadrelay(OL) contacts.
Momentarilypressingthe start pushbuttoncompletethepathforcurrent flowand energies themotorstarter(M).This
closetheassociatedMandMa(auxiliarycontactlocatedinthemotorstarter)contacts.Whenthestartbuttonisreleased,
current
Continues to flow through thestop button and the Ma contacts, and the M coil remains energized. The motor will run
untilthenormallyclosed stopbuttonis pressed,unlesstheoverloadrelay(OL)contacts open.whenthestopbutton is
pressed,thepathforcurrentisinterrupt,openingtheassociated MandMacontacts andthemotorstop.

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Chapter 3
SCADA
Introduction
SCADA is not a specific technology, but a type of application
“SCADA” stands for Supervisory Control And Data Acquisition –any application can gets data
about a system in order to control the system is a SCADA application’’ it is a purely software
package that is positioned on top of hardware to which it is interfaced , in general via Programmable
logic controller (PLCs), or other commercial hardware modules.
In other words
SCADA: the term refers to a large scale, distributed measurement (and control) system. SCADA are
used to monitor or to control chemical, physical or transport process.
SCADA it is refers to an industrial control system a computer system monitoring and controlling
process. The process can be industrial, infrastructure or facility describe below
Industrial process: it is includes those of manufacturing, production, power generation,
fabrication, and refining and process may be in continuous, batch, repetitive or discrete or
modules.
Infrastructure process: it may be public or private and water treatment and distribution,
wastewater collection, and treatment, oil and gas pipelines , electric power transmission and
distribution, and large communication systems.

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Facility Process: it is occur both in public facilities and private ones, including building, airports,
ship and space station. The monitor and control HVAC, access and energy consumption
A SCADA system usually consists of following subsystem
 A Human – Machine interface (HMI) is the apparatus which present process data to
human operator, and through this, the human operator monitor and control the process.
 A supervisory (computer) system, gathering (acquiring) data on the process and sending
commands.
 Remote terminal unit (RTU) connection to sensors in the process and converting sensors
signals to digital data and sending digital data to the supervisory system.
 Programmable Logic Controller (PLC) used as field devices because they are more
economical, versatile, flexible configurable than special purpose -RTUs.
 Communication infrastructure connection the supervisory system to the Remote Terminal
Unit.
Systems Concepts
The terms SCADA usually refer to a central system that monitors and controls a complete site. The bulk of
the site control is actually performed automatically by a Remote Terminal Unit (RTU) or by a
programmable Logic controller (PLC). Host control functions are almost always restricted to basic site
override or supervisory level capability.
EX: A PLC may control the flow of cooling water through part of an industrial process, but the SCADA
system may allow operators to change the set points for the flow, and enable alarm condition, such as loss
of flow and high temperature, to be displayed and recorded. The feedback control loop passes through the
RTU or PLC while the SCADA system monitors the overall performs of the loop.

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TAGS (POINTS)
It is logical name of a variable or object that be used in our animation of a plant.
Tags are two types
 System defined Tags
 User defined tags
System defined tags
It is represent the system value in the SCADA it is represented by dollar sing $

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User defined tags
This tag are defined by the user or programmer
Except (A,S) are not defined.
Trends:
it is used for graphical representation of process
Two types
 Real times trends
 Historical Times trends
Classification of tags
 Direct tags
 Indirect tags
Direct tags
These tags are directly used by the programmer to represent the value of plant or variable
Indirect tags
These tags are used by the another tags to show or represent the value of plant or variable
Direct tags
Memory tags: these tags having no connection with process the plant.

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ALARM
An important part of most SCADA implementation is alarm handling. The system monitors whether certain
alarm conditions are satisfied, to determine when an alarm event has occurred. Once alarm event has
been detected, one or more action are taken (such as the activation or remote SCADA operators are
informed) in many case, a SCADA operate may have to knowledge the alarm event, these may be
deactivate some alarm indicators whereas other indicators remain active until the alarm conditions are
cleared. Alarm conditions can be explicit - for example, an alarm point is a digital status point that has
either the value NORMAL or ALARM that is calculated by a formula based on the values in other analogue
and digital points- or implicit: the SCADA system might automatically monitor whether the value in an
analogue point lies outside high and low limit values associated with that point. Examples of alarm
indicators include a siren, a pop-up box on a screen, or a colored or flashing area on a screen (that might
act in a similar way to the "fuel tank empty" light in a car); in each case, the role of the alarm indicator is to
draw the operator's attention to the part of the system 'in alarm' so that appropriate action can be taken.
In designing SCADA systems, care is needed in coping with a cascade of alarm events occurring in a short
time, otherwise the under lying cause (which might not be the earliest event detected) may get lost in the
noise. Unfortunately, when used as a noun, the word 'alarm' is used
rather loosely in the industry; thus, depending on context it might mean an alarm point, an alarm
indicator, or an alarm event.
SYSTEM COMPONENTS
The three components of a SCADA system are:
1. Multiple Remote Terminal Units (Also knows as RTUs or outstation)
2. Central control Room with host computer (s)
3. Communication infrastructure

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Remote Terminal Unit (RTU)
The RTU connects to physical equipment and read status dada such as the open/close status from a switch
or a valve, read measurements such as pressure, flow, voltage or a valve, or setting the speed of a pump.
The RTU can read digital status data or analogue measurement dada, and send out digital commands or
analogue.
Salient feature of modern SCADA system
1. User- friendly (X-windows/graphic) interface.
2. Automatic control.
3. Off-line processing.
4. Integrated environments.
5. Extensive Historical data manipulation.
6. Extremely high data throughput
7. On-line complex electrical network analysis.
8. Real time supply/ demand- side economic calculations.
9. Automatic voltages and power factor correction.
10. Distributed processing power.
Benefits HMI/SCADA
1.Powerful monitoring and control over your production
2.Ease of use for New and experienced users.
3.Robust connectivity to other software, system and devices
4.True client /server Architecture for ease Scale ability
5.Powerful thin client technology.
6.Sophisticate Alarm and trending.

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SCADA Recommended
1. LAN /WAN support
2. Import from multiple PLC system
3. Support for low bandwidth operation.
4. Secure & flexible.
5. Low CPU & memory requirements.
6. Drives work on Rs232, 422, 485, TCP/IP.
7. Unlimited number of tags (tags support 80 char).
8. Graphic (transparent color support, advanced animation without coding, import graphic
window bitmap –Auto Cad, fax image.
9. Supervision
10. Controlling
11. Dada collection
12. Interface of PLCs
13. Alarm.

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Chapter 4
Human Machine Interface (HMI)
Introduction
HMI is the smallest form of SCADA which is used for monitoring and controlling and it is
combination of hardware and software.
Human machine Interface:
The HMI/SCADA industry was essentially out of a need for user friendly front-end to a control
system containing programmable logic controller (PLC). While a PLC does provide automated,
preprogrammed control over a process, they are usually distributed across a plant, making a difficult
to gather data from them manually. additionally, the PLC information are usually in crude user-
unfriendly format. The HMI/SCADA gather information from the PLCs via some form of
communication method, and combines and formats the information. Since the early1990s the role of
SCADA system in large civil engineering solutions has changed, requiring them to perform more
operations automatically. A sophisticated HMI may also be linked to a database to provide instant
trending diagnostic data, scheduled maintenance procedures, logistic information, detail schematics
for a particular sensors or machine, expert –system troubleshooting guides.
Since about 1998 , virtually all major PLC manufacture have offered integrated HMI/SCADA
system, many of them using open and non proprietary communication protocols.
Types of HMI
1. Keypad
2. Touch screen
3. Keypad + touch scree

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Difference between SCADA and HMI
SCADA
It is software
It is work at low temperature
Screen ratio of SCADA is large
Local and Remote control
Data base connectivity is possible
Range of SCADA
HMI
it is combination of s /w and h/w
it is work at high temperature & low
Screen ratio of HMI is Low i.e 6 inch
LAN area Control
Data base connectivity is not possible
Range of HMI is 100m
Instrumentation
Instrumentation is a branch of engineering electric (science) which is used for measurement of
process parameters and electric parameters it include, flow meter, thermocouple, level instrument
etc.
Transducer:
It is device which converted one form of engineering into another form of energy.
Sensors:
It is transducer which converted one form of energy into measurable form of energy.

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Types of sensors
1. Flow meter
2. Pressure sensors
3. Ambient meter
Transmitter
It is a device which is used for the transmission of signal over long distance so generally
used for transmitter.

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Chapter 5
Application for PLC in substation automation & SCADA
 Electric power generation, transmission and Distribution.
 Manufacturing industries.
 Mass transit & whether management system
 Traffic signals.
 Cement and petrochemicals industries.
 Automobiles industries

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There are many applications for PLC for substation automation, distribution automation &
SCADA system. As utility engineers become more familiar with capability of PLCs and PLC
manufactures develop a new substation specific products. The number and type of potential
applications continues to increase.
 RTU (Remote terminal Unit) emulation & replacement
 Alarm reduction & intelligent messaging
 Utilize existing SCADA protocols
 Ethernet, TCP/IP
 Multiprotocol, DNP 3.0, Modbus plus
 Analog & Discrete I/O
 Protection & control
 Protective relay interface/ intrection
 Automatic switching
 Automatic transfer schemes
 Circuit breaker control &interlocking
 Feeder automation & fault recovery
 Automatic service restoration
 Emergency load Shedding
 Station HMI- Graphic user interface (GUI)
 Remote control
 Demand control

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CONCLUSION
This report has discussed the role that programmable logic controller have in efficient design and control
of mechanical process. Also discussed was the understanding,
 AUTOMATION, SCADA, HMI, Instrumentation and the programming involved with
it. Finally, the report has discussed as complete Automation, like a , relay,
Components, history.
Programmable Logic Controller, history, advantages. Inside PLC etc…
 PLC components, understanding Ladder logic, example
 SCADA: this section contains basic introduction of SCADA, features,
Recommended, Tags, Trends
 Difference between SCADA & HMI.
 HMI: This section contains basic HMI, types of HMI, introduction.

Page 55
REFERENCE
1. Pollet, Jonathan, SCADA Security Strategy, Plant data Technology, August 8, 2002
2. www.scadanews.com
3. www.princeton-indiana.com/wasetewater/Pages
4. www.ref.web.cern.ch/ref/CERN
5. www.sss-mag.com/scada.html
6. www.scada.com
7. www.scrib.com

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BIBLIOGRAPHY
1. Study material by Prolific automation system pvt. Ltd.
2. Study material by Futronix automation pvt. ltd.
3. Programmable logic by John. R . Hockwarth
4. Controllers Programmable logic by L.N.Bryan
5. Controllers E.A.Bryan
6. Programmable logic by W.Batton
7. Controllers Automatic manufacturing by Hugh Jack
8. System with PLC Communication technology guidelines for SCADA system, power
delivery by Marihart, D.J

Training report 2012 2015-sonu yadav

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