PLC SCADA

INDUSTRIAL TRAINING

SUBMITTED BY:
ANMOL
ECE

WHAT IS AUTOMATION

Making products under the control of computers

and programmable controllers is known as
automation.
Manufacturing assembly lines as well as stand
alone machine tools and robotic devices fall into
this category.
It is delegation of human control functions to
technical equipment for increasing the
productivity, quality, and increasing the safety in
working conditions thereby reducing the
manpower and cost.

INSUSTRIAL AUTOMATION

Now a days, every small and large industry

employ automation.
In manual control, an operator periodically reads
the process and adjusts the input accordingly.
Quite hectic!
In automation control, measurements and
adjustments are done automatically on a
continuous basis. Quite convenient!

PLC
(PROGRAMMABLE LOGIC CONTROLLER)

It is microprocessor based solid state/industrial

computer that perform discrete or sequential
logic.
It was developed to replace mechanical relays,
timers, counters.
The early PLCs were used to reduce the
changeover time, wiring/re-wiring.
The PLC programming procedures replaced the
rewiring a panel full of wires, relays, timers,
counters etc.

ADVANTAGES

Reliability in operation.
Flexibility in control and programming techniques.
Online offline modifications.
Small physical size, shorter project time.
In house simulation and testing of project.
Speed of operation.
Ease of maintenance and troubleshooting.
Ability to communicate and networking with
computer system in plant.
Documentation and security.
Designed to work in all types of industrial conditions.

MICROLOGIX 1000
PROGRAMMABLE CONTROLLER

ARCHITECTURE OF A PLC
(Toggle or Push
buttons,
proximity or
pressure sensors)
INPUT
DEVICES

POWER
SUPPY

PLC

(24V DC,
120V AC)

OUTPUT
DEVICES
(Displays &
Monitors)

MEMORY
(External
memory module)

INTERFACE
(SCADA or HMI)

HARDWARE OVERVIEW

COMPUTER

DOWNLOAD
UPLOAD

PLC

DATA TRANSMISSION - SERIAL

SYSTEM(PORT)
(RS 232)

Baud Rate- 9.6 Kbps to 19.2 Kbps

Driver softwares- RS Linx Classic, RS 232 & DF Drivers

Programming software- RS Logix 500

PLC(PORT)
(DF port)

WORKING
Source mode:
Sink mode:

+ve supply is given to the PLC.

-ve supply is given to the PLC.

The sink and source modes mainly define the way in which the I/O is
connected to the I/O of the PLC.

PROGRAMMING THE PLC

Programming language used: LADDER

language( ladder 2). The programming can be
done with simple contacts that simulate the
opening and closing of relays, counters, timers,
shift registers and other math operations.

BASIC SYMBOLS:

Input symbols:

XICXIO-

Output symbols: OTEOTLOUL-

ADDRESSING FORMAT : Identifier: slot address(if any).word

address/bit
DATA FILES: micrologix 1000 contain the status information
associated with the external I/O and all other instructions we
use in our main and subroutine ladder program files.
These files are organized by the type of data they contain. Data
file types are:

PLC TIMER/COUNTER FUNCTION

TIMER ON(TON)

COUNTER UP

MATH INSTRUCTIONS

APPLICATIONS

Material Handling
Packaging Applications
General Industrial Machinery
Printing
Food and Beverage
Pharmaceutical
Water Wastewater / SCADA
Clutch/Brake control
Position Control - Pick-and-place / Conveyor

SCADA

Supervisory Control And Data Acquisition

It is a software through which we can create
visualization of any industrial process.
Earlier, PLCs were programmed, download the
program in it and it used to run for years
The problem- no one knew whats happening
inside the PLC.
Solution= PLC+SCADA

Supervisory Control and Data Acquisition

Supervisory means Monitoring

entire system through
Control means Controlling
GUI representation
of working Status ,of the the entire System such as
ON/OFF operation ,
entire system
Speed controlling,
temperature Controlling

Data Acquisition
mean collecting
data Information
from Different
controller, Sensor ,
Drives , Motor which
are connected at
distance through wire
, Ethernet , wireless

USEFULNESS OF SCADA

Production Division
Quality Division
Maintenance Division
Engineering Division
Manufacturing Division

PRODUCTION DIVISION

Real time production status

Production schedules
Production Information mgt.

QUALITY DIVISION

Data integrity and quality control

It is an open platform for statistical analysis

MAINTENANCE DIVISION

Improved troubleshooting and de-bugging

Plant can be viewed remotely
Co-ordination between maintenance & mgmt. reduces
unscheduled downtime.

MANUFACTURING DEPTT.

Makes operation easier and repeatable with its real time

functionality.
Secured real time operation are maintained with windows.

TAGS

It is the address of the memory location where

signals are being saved.
We define a TAG in order to use it in the SCADA
software (Intouch wonderware).
TYPES : 1) Analog 2) Digital 3) Strings
These are further associated with either
Memory or I/O type tags.
PC-SCADA Memory analog/digital/string tag
PLC-SCADA - I/O analog/digital/string tag

DYNAMIC PROCESS GRAPHIC

FEATURES OF SCADA

Dynamic Process Graphic

Trends
Alarms
Security
Device Connectivity
Recipe Management
Database Connectivity
Script for logic development

TYPES OF SCADA PACKAGES

1.

2.

3.

D + R + N With this package development &

editing of the application is possible runtime
monitoring & control of the plant is possible &
networking is possible.
R + N With this package development &
editing of the application is not possible ,
runtime monitoring & control of the plant is
possible & networking is possible.
Factory Focus - With this package
developments & editing of the application is
not possible . Runtime monitoring is possible
but not control of the plant is possible. This
package is used as a view node

SCADA SOFTWARE

Wonderware- Intouch
Rockwell- RS view32
Siemens- winCC
GE- Intellation

PLC-SCADA COMMUNICATION

PLC PROJECT
(SILO SIMULATION)

Completely design and de-bug a ladder control circuit

which will automatically position and fill the boxes which
are continuously sequenced along the conveyor.

The sequence can be stopped and re-started at any time

using the panel mounted Stop and Start switches.

The RUN light will remain energized as long as the system

is operating automatically.

The RUN light, Conveyor Motor and Solenoid will deenergize whenever the system is halted via the STOP
switch.

The FILL light will be energized while the box is filling.

SCADA PROJECT
(AUTOMATIC BOTTLE FILLING PLANT)

The project SCADA CONTROLLING AUTOMATIC BOTTLE FILLING

PLANT has a motive to automate the filling of the liquid bottle
from the tanks with the help of controlling through scada
software.

In this plant there are following major operations to be

performed.The first one is designing the whole plant as it is in
the field.

secondly filling of the bottle to the required level with the help
of 2 tanks and then transferring the contents of bottle to another
bottle in different conveyor and transporting it .

For different slider values the operation is performed.The bottle

coming through conveyor is filled up by 2 tanks containing liquids
of different colour and filling the bottle upto 50%.In the end
when container becomes full it will transfer its material to
another empty container on a different conveyor.

THANK YOU!!!