Training Seminar

On

INDUSTRIAL AUTOMATION

PRESENTED BY:

Chandramaul Sen Electrical Engineering

3611605

Department of Electrical Engineering

GEETA INSTITUTE OF MANAGEMENT AND TECHNOLOGY, KURUKSHETRA, INDIA

 

Introduction to Organisation

Advance Technology, Chandigarh

Advance Technology, Chandigarh is an ISO 9001:2008 Certified Company deals in the field of Hardware Development, Embedded Products Development, Security & Surveillance and Engineers Training Programs.

Advance Technology offer various Technical Education solutions, Products & Development tools to Engineering colleges, Universities, research organizations.

Advance Technology has developed a number for private as well government organizations.

PROGRAMMABLE

LOGIC CONTROLLER

PLC

The PLC is an assembly of solid state digital logic elements design to make logical decisions and provide outputs.

PLC is programmed interface between input sensor &output device.

Programmable Logic Controllers

Sequential logic solverPID Calculations.Advanced SubroutinesBIT Operations.Data Transfer.Text Handling.

Programmable Logic Controllers Applications : Machine controls, Packaging, Material handling, similar

Sequential task as well as Process control

Advantages of PLC : They are fast and designed for the rugged industrial

environment. They are attractive on Cost-Per-Point Basis. These Devices are less Proprietary ( E.g.. Using Open Bus

Interface.) These Systems are upgraded more Capabilities with

dedicated PID and Ethernet Modules.

Disadvantages of PLC : PLC one time cost is high To maximize PLC performance a number of IO Modules to be

added. PLC hold only one copy of program.

P L C Components(Hardware)

Central Processing Unit (CPU)

Input ModulesOutput ModulesPower Supply Bus systemRack(Rail)

Central Processing Unit

It is a micro-controller based circuitry. The CPU consists of following blocks :

Arithmetic Logic Unit (ALU), Program memory Process image memory (Internal memory of CPU) Internal timers ,counters and Flags .CPU performs the task necessary to fulfill the PLC

functions. i.e. Scanning I/O bus traffic control, Program execution, Peripheral and External device communication, data handling and self diagnostics.

Input module

These modules act as interface between real-time status of process variable and the CPU.

Analog input module : Typical input to these modules is 4-20 mA, 0-10 V

Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple (mV)

Digital input module : Typical input to these modules is 24 V DC, 115 V AC, 230 V AC

Ex. : Switches, Pushbuttons, Relays, pump valve on off status

These modules act as link between the CPU and the output devices in the field.

Analog output module : Typical output from these modules is 4-20 mA, 0-10 V

Ex : Control Valve

Digital output module : Typical output from these modules is 24 V DC, 115 V AC, 230 V AC

Ex. : Solenoid Valves, lamps, Actuators, Pump valve on off

control

Output module Output module

I/O MODULE SPECIFICATION

COST INPUT VOLTAGE ON-STATE INPUT VOLTAGE RANGE AMBIENT TEMP RATING INPUT DELAY – NOMINAL OUTPUT VOLTAGE MAX O/P CURRENT ELECTRICAL ISOLATION –

Power Supply

The power supply gives the voltage required for electronics module (I/O, CPU, memory unit) of the PLC from the line supply.

The power supply provides isolation necessary to protect the solid state devices from most high voltage line spikes.

As I/O is expanded, some PLC may require additional power supplies in order to maintain proper power levels.

Advantage of PLC Over Relay

RELAY PLC 1-More wiring 1-Less wiring

2-Changes difficult 2-Changes easy

3-More power 3-Low power

4-More maintenance 4-Solid state reliability

5-Difficult to expand 5 -Easy to expand

PLC Cycle

Sense the Input Process the LogicGive Output

OutputsCPUInputs

Configuration of PLC : Allen Bradley

CPU

Power Supply I/O Modules

PLC Programming Standards

Ladder Diagram Function Block Diagram Sequential Function Chart Structured Text Language

PLC Selection Criteria

Cost of hardware, I/O requirement CPU memory Spare parts& Maintenance, Reliability, Flexibility& Integration of High-level Application. Compatible Protocol

PLC : Protocol

• It is a set of rules for data transmission when PLC is connected to network

• RS-232 (Recommended standard)• RS-485• MPI(Multi point Interface)• Profibus• DH(Data Highway)• Ethernate• Controlnet

PLC Applications

Program of Bottle Filling Plant

Program of Bottle Filling Plant

Program of Blinking of 2 Lamps

Supervisory Control and Data Acquisition

(SCADA)

SCADA

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 sizes of such plants are range from a few 1000 to several 10 thousands input/output (I/O) channels.

Hardware ArchitectureOne distinguishes two basic layers in a SCADA system: the "client layer" which caters for the man machine interaction and the "data server layer" which handles most of the process data control activities.

The data servers communicate with devices in the field through process controllers. Process controllers, e.g. PLCs, are connected to the data servers either directly or via networks or field buses that are proprietary (e.g. Siemens H1), or non-proprietary (e.g. Profibus).

Data servers are connected to each other and to client stations via an Ethernet LAN. The data servers and client stations are NT platforms but for many products the client stations may also be W95 machines.

Hardware Architecture

Advantages & Disadvantages of SCADA

Advantages• Increase Efficiency

- Minimize Fault Response Time- Reduce Planned Downtimes- Isolate and Precisely Locate Faults  

• Maximize Profitability- Reduce Failures / Unplanned Downtimes- Reduce Operations Overhead- Reduce Manpower Requirement- Maximize (Achieve Expected) Equipment Life Time

• Maximize Safety- Public Safety- Site Safety

Disadvantages

• Cost is high to install and maintain.• Additional system failure modes and can

be a security loophole.

Thank You