Futuronix Automation-Practical Training Report on Automation

8/4/2019 Futuronix Automation-Practical Training Report on Automation

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Problem 8 : Using NO pb, when pb pressed counter will decrement its

value, when counter current value is equal to 2 light 1 get on, when counter

current value equal to 5, light 2 get on, when current value equal to 8 them

light3 get on, when current value is equal to9 them light 4 get on, counter get

reset using NC switch?

NC / Nc

RRr

NO / No

NO / No

%Q0.0

%Q0.1

%Q0.2

R

E

S

C U D

CD F

%C0.V=2

%C0.V=5

%C0.V=9


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Problem 9: Make a logic using NC pb such that when NC pressed light 1 get on

immediate, after 5sec light 2 get on for 2 sec, this cycle will repeteuntil counter get done. Every time when cycle get complete counter will

increment its value till the counter get done, when counter get done light 1

and light 2 get off and light 3 will get on to show counter is done, systemwill work again when counter is reset using NO pb?

Engg. College, Bikaner. Electrical 4th year. Vishal kumar Sharma.

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NC / No NC / Nc %M0

%M0

%M0 %TM1.Q %Q0.2 %Q0.0

%M0 %Q0.0 %Q0.1

TM0

10 sec

%M0 %TM0.Q

TM1

10 sec

%NO / Nc

%Q0.1


3

R E

S

D

CU

CD F


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5. Programming with operator block:

Operator block: Operator block remain always right side of the screen and

the mean of his is that we transfer or perform any mathematical operation on

two memory wards.

According to figure we put the value of memory ward1 in to the memory

Ward 2 by this sentence.

Problem 10: Value of two memory wards add and result will move in

another memory wards, If value of this memory wards is greater than 1 and

less then 5 them counter will increment its value by one, when counter get

done light 1 will get on?

%NO / No

%M0

%M0 %Q0.0

PLC Serial number: - For any type of PLC the serial number of PLC


4

%MW0:=%MW1

%MW2:=%MW1+%MW0

%MW2>1 %MW2


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provides or show all the information of it, it tell us all the important and

practical use related information of the PLC, it gives us the following

information.

1. Name of processor or company.

2. Type of the PLC.

3. The power rating of PLC.

4. Number of input and output for that PLC.

5. Type of input and output, etc.

Examples:

1. Let we have a Twido soft PLC which serial number is

TWDLCAA16DRF. This

Plc number give us the following information.

Serial number TWDL C AA 16 D R F

TWDL: Twido processor (processor)

C: compact (Type of PLC)

M: modular

AA: 230v ac. (Operating voltage)

A: 24v, dc

16: Number of input and output ports.

D: 24v,dc (type of input signal)

A: Analog.

R: Relay (type of outputs)


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U: Transistor output.(sink type)

T: Transistor oputpu(source type)

F: Non removable

K: Removable.

2. Lets we have a allen bradely PLC and the serial number is

1762L24BWA.

The serial number is 1762 L 24 B WA

1762: Serial number (Buleten number)

L: Processer (microcontoaller)

24: No of input and outputs.

B: 24v ,dc (Type of input signal)

A: 120/230 v, ac.

WA: Type of output

W: relay output

A: Triac output

B: Mosfet outputN: transistor output.

Project:


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Project on general life problems.

Problem: For a twido soft Plc make a logic for the traffic point in which

we have four way rods and for every side we have 3 lights, green, red and

yellow. For each side yellow blow for 10 second before the green, and

important condition is that on one side only one light can glow at particular

time and at each side always one light remain glow also, and all the system

remain continue for a period which is set by the traffic inspector after that

time system goes off and it start again while inspector start it by a push

switch from traffic control room?

%NO / No %M1 %M0

%M0

%M0 %TM0.Q %Q0.0 (G1)

%TM1.Q %Q0.1(G2)

%TM2.Q %Q0.2(G3)

%TM3.Q %Q0.3(G4)


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%M0 %TM0.Q %Q0.4(R1)

%TM1.Q %Q0.5(R2)

%TM2.Q %Q0.6(R3)

%TM3.Q %Q0.7(R4)

%Q0.8

%M0 %Q0.3 %TM4.Q %Q0.8(Y1)

%Q0.9

%Q0.0 %TM4.Q %Q0.9(Y2)

%Q0.10


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%Q0.1 %TM4.Q %Q0.10

%Q0.11

%Q0.2 %TM4.Q %Q0.11

%TM1.Q

%M0 Ton 0

%TM3.Q %TM1.Q

%M0 %TM0.Q Ton 1

%TM1.Q %TM2.Q

%M0 %TM1.Q ton2

%TM2.Q %TM3.Q

%M0 %TM2.Q T on3


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%TM3.Q %TM0.Q

%M0 %Q0.0 %Q0.9 T0n 4

10 sec

%Q0.1 %Q0.10

%Q0.2 %Q0.11

%Q0.3 %Q0.8

% NO / No

%M1%TM0.Q

SCADA (Supervisory Control and Data Acquisition) : -

Earlier Plcs use to be black boxes. You program the PLC, download the

program in it, and it will run for years. But the problem with his\is was that

you really dont know what is happening inside the PLC. Now a days


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R E

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DCU

CD F


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automation system contains PLCs and DCADA software. If you use PLC

and SCADA combination the advantages you have is you have better

monitoring and control of the plant and also you have access to the

information the way you want. DCADA enables engineers, supervisors,

managers and operators to view and interact with the workings of entire

operations though graphical representation of their production process.

SCADA runs on a PC and is generally connected to various PLC and

other peripheral devices. It enables you to generate applications for the

most demanding requirements of plant engineers, operators, supervisors and

mangers, tailored precisely to the needs of each plant DCADA constantly

gathers data fro the plant in real time, stores and processes it in the database,

evaluates and generates alarms, displays information to plant operators to

plant operators, supervisors and managers and can issue instructions to

PLC on the plant floor.

Features of SCADA: -

1. Dynamic process graphic mimics developed in SCADA software

should resemble the process mimic SCADA should have good library of

symbols so that you can develop the mimic as per requirement, once the


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operator sees the screen he should know what is going on in the plant.

2. Real time and historical trend the trends play very important role in

the process operation. If your batch fails or the plant trips, you can

simply go to the historical trend data and do the analysis. You can have

better look of the parameters through the trends, for example we

commission a SCADA system for Acid Regeneration plant where the

plant has to be operated on 850-deg temperature. If the operator operates

the plant at 900-deg you can imagine how much additional lpg he is

potion into the reactor. Again what will happen to the bricks of the

reactor. So the production managers first job will be to go through the

trends how the operators are operating the plant. Even when the plant

trips there are more than 25 probable reasons for the same but if you go

throat the history trends, its very easy to identify, the problems.

3. Alarms have a very critical role in automation . Generally you have

alarm states for each input and outputs like your temperature should not

cross 80-deg or lever should be less that 60. So if the paramours goes in

alarm. State the operator should be initiated with the alarm. Most of

the SCADA software support four types of alarms like LOLO, LO ,HI,

HIHI. Dead band the value of dead band defines the range after which a high

low alarm contain returns to normal.

Alarms are most important part of plant control applications because


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the operator must know instantly when something goes wrong. It is often

equally important to have a record of alarm and whether an alarm was

acknowledged. An alarm occurs when something goes wrong . It can signal

that device or process has ceased operating within acceptable, predefined

limits or it can indicate breakdown, wear or process malfunction.

4. Recipe management is an additional feature. Some DCADA software

support it some do not. Most of the plants are manufacturing multi products.

When you have different product to manufacture you just have to load the

recipe of the that particular product.

5. Security is one facility people generally look for. You can allocate

certain facilities or features to the operator, process people, engineering dept.

& maintenance dept. for example operators should only operate the system.

he should not be able change the application. The engineers should have

access to changing the application developed.

6. Device connectivity you eoll find there are hundreds of automation

hardware manufacturer like modicon, simens, allen tradley . Everybody has

there own way of communication or we can say they have there own

communication protocol. SCADA software should have connectivity to the

different hardware used in automation. It should not happen that for

modicon I am buying one software and for siemens another one. The

software like Aspic or Wonderware has connectivity to almost all hardware

used in automation.


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7. Database connectivity now a days information plays very important

role in any business. Most manufacturing units go for enterprise resource

planning or management information system.

Usefulness of SCADA: -

1. Production Dept:

a. Real time production status: manufacturing status is updated in

real time in direct communication to operator and control device.

b. Production schedules: production schedules can be viewed and

updated directly .

c. Production information mgt: production specific information is

distributed to all.

2. Quality Dept:

a. Date integrity and quality control is improved by using a

common interface.

b. It is an open platform for statistical analysis.

c. Consolidation of manufacturing and lab data.

3. Maintenance Dept:

a. Improved troubleshooting and debugging: Direct connection to

wide variety of devices, displays improves troubleshooting,

reduces diagnostic time.


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b. Plant can be viewed remotely: Notification can include pagers,

emails and phones.

c. Co-ordination between maintenance and mgt reduces

unscheduled downtime.

4. Engineering Dept:

a. Integrated Automation solutions reduce design and

configuration time.

b. Common configuration platform offers flexibility for constant

configuration in all areas .

c. Capable of connecting to wide variety of systems. Reduces start

up time and system training with industry proven open interfaces.

5. Manufacturing Dept:

a. Unscheduled down time is reduced due swift alarm detection

and event driven information.

b. Makes operations easier and more repeatable with its real time

functionality.

c. Secured real time operation are maintained with windows.

General Terminology of SCADA: -

1. What is a Tag: A tag is a logical name for a variable in a device or

local memory. Tags that receive data from some external devices such as

programmable logic controllers or servers are refereed to as input and


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output tags. Tags that receive data internally from software are called

memory tags.

2. Analog Tags: Store a range of values are called analog tags form

example temperature, flow etc.

3. Discrete Tags: To store values such as 0 or 1 are called discrete tags

form example pump, valves etc.

4. System Tags: System tags store information generated while the

software is running including alarm info and system time and date.

5. String Tags: String tags are used to store ASCII strings a series of

characters or whole word. The max string length is 131 characters.

Miscellaneous links: -

1. Visibility: Visibility used to control visibility of an object based on

the value of a discrete tag name or expression.

2. Blink: Blink used to make an object blink based on the value of a


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discrete aflame or expression.

3. Orientation : Orientation used to make an object rotate based on the

value of a aflame.

4. Disable: Disable used to disable the touch functionality of objects

based on the value of a tag name of expression. Often used as part of a

security strategy.

5. Value display links: Value display links provide the ability to use a

text object to display the value of a discrete, analog or string tag name.

6. Percent fill links: Percent fill links used to provide ability to vary the

full level of a filled shape according to the value of an analog tag name or

an expression that computes to an analogy value.

Animation links: -

1. Touch links: Touch links allow the operator to input data into the

system. Form example operator may turn the valve on or off, enter a new

alarm set point, run a complex logic script etc.

2. Touch pushbuttons: Touch pushbuttons are used to create object

links that immediately perform an operation when clicked with the mouse

or touched. These operations can be discrete value changes, action script

executions, and show or hide window commands.

3. Color links : Color links are used to animate the line color, fill color

and text contour of an object. Each of these color attributes can be made


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dynamic by defining a color link for the attribute. The color attribute may

be linked to the value of a discrete expression, analogue expression,

discrete alarm status or analog alarm status.

Trends in SCADA: -

There is a trend for PLC and HMI/SCADA software to be more "mix-

and-match". In the mid 1990s, the typical DAQ I/O manufacturer

supplied equipment that communicated using proprietary protocols over a

suitable-distance carrier like RS-485. End users who invested in a

particular vendor's hardware solution often found themselves restricted to

a limited choice of equipment when requirements changed (e.g. system

expansions or performance improvement). To mitigate such problems,

open communication protocols such as IEC870-5-101/104, DNP3 serial,

and DNP3 LAN/WAN became increasingly popular among SCADA

equipment manufacturers and solution providers alike. Open architecture

SCADA systems enabled users to mix-and-match products from different

vendors to develop solutions that were better than those that could be

achieved when restricted to a single vendor's product offering.

Towards the late 1990s, the shift towards open communications

continued with individual I/O manufacturers as well, who adopted open

message structures such as Modbus RTU and Modbus ASCII (originally

both developed by Modicon) over RS-485. By 2000, most I/O makers

offered completely open interfacing such as Modbus TCP over Ethernet


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http://en.wikipedia.org/wiki/RS-485http://en.wikipedia.org/wiki/DNP3http://en.wikipedia.org/wiki/Open_architecturehttp://en.wikipedia.org/wiki/RS-485http://en.wikipedia.org/wiki/DNP3http://en.wikipedia.org/wiki/Open_architecture


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remotely introduces security considerations. While these considerations are

already considered solved in other sectors of internet services, not all entities

responsible for deploying SCADA systems have understood the changes in

accessibility and threat scope implicit in connecting a system to the internet.

Security issues:-

The move from proprietary technologies to more standardized and open

solutions together with the increased number of connections between

SCADA systems and office networks and the Internet has made them more

vulnerable to attacks - see references. Consequently, the security of

SCADA-based systems has come into question as they are increasingly seen

as extremely vulnerable to cyberwarfare/ cyberterrorism attacks.

In particular, security researchers are concerned about:

the lack of concern about security and authentication in the design,

deployment and operation of existing SCADA networks

the mistaken belief that SCADA networks are secure because they are

purportedly physically secured

the mistaken belief that SCADA networks are secure because they are

supposedly disconnected from the Internet

SCADA systems are used to control and monitor physical processes,

examples of which are transmission of electricity, transportation of gas and

oil in pipelines, water distribution, traffic lights, and other systems used as

the basis of modern society. The security of these SCADA systems is

important because compromise or destruction of these systems would impact


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http://en.wikipedia.org/wiki/Internethttp://en.wikipedia.org/wiki/Internet


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multiple areas of society far removed from the original compromise. For

example, a blackout caused by a compromised electrical SCADA system

would cause financial losses to all the customers that received electricity

from that source. How security will affect legacy SCADA and new

deployments remains to be seen.

There are two distinct threats to a modern SCADA system. First is the

threat of unauthorized access to the control software, whether it be human

access or changes induced intentionally or accidentally by virus infections

and other software threats residing on the control host machine. Second is

the threat of packet access to the network segments hosting SCADA devices.

In many cases, there is rudimentary or no security on the actual packet

control protocol, so anyone who can send packets to the SCADA device can

control it. In many cases SCADA users assume that a VPN is sufficient

protection and are unaware that physical access to SCADA-related network

jacks and switches provides the ability to totally bypass all security on the

control software and fully control those SCADA networks. These kinds of

physical access attacks bypass firewall and VPN security and are best

addressed by endpoint-to-endpoint authentication and authorization such as

are commonly provided in the non-SCADA world by in-device SSL or other

cryptographic techniques.

Many vendors of SCADA and control products have begun to

address these risks in a basic sense by developing lines of specialized

industrial firewall and VPN solutions for TCP/IP-based SCADA networks.


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http://en.wikipedia.org/wiki/Firewallhttp://en.wikipedia.org/wiki/VPNhttp://en.wikipedia.org/wiki/Firewallhttp://en.wikipedia.org/wiki/VPN


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Additionally, application whitelisting solutions are being implemented

because of their ability to prevent malware and unauthorized application

changes without the performance impacts of traditional antivirus scans Also,

the ISA Security Compliance Institute (ISCI) is emerging to formalize

SCADA security testing starting as soon as 2009. ISCI is

conceptually similar to private testing and certification that has been

performed by vendors since 2007. Eventually, standards being defined by

ISA99 WG4 will supersede the initial industry consortia efforts, but

probably not before 2011 .

The increased interest in SCADA vulnerabilities has resulted in

vulnerability researchers discovering vulnerabilities in commercial SCADA

software and more general offensive SCADA techniques presented to the

general security community. In electric and gas utility SCADA systems,

the vulnerability of the large installed base of wired and wireless serial

communications links is addressed in some cases by applying bump-in-the-

wire devices that employ authentication and encryption rather than

replacing all existing nodes.

-:Conclusion:-

The automation of any system or any industry is necessary in the

present


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comparative ward for the better performance of the system or industry. The

main and most important part of a automatic system is a PLC and

SCADA.

By the use of plc we can change any system as according to our

requirements without changing in the hardwares. The many other benefits

are also by them it is used like its required less space and less power to

operate, it has long life, the changing in logic is easy etc. For the use of a plc

the programming is must, with out the program we can not use the plc, for

the different plcs of all the companies the method of programming and the

logic remain same but the addressing is changed, the addressing is also

available from the softwares. So the most important part is programming

for a plc according to the requirements.

SCADA is the second important part of the automation. It is used

by the plcs, by the scada softwares we can design mimic of each field

system or components and can measure in our pc which is placed in our

control room. And we can control or change the value of each components

through our computer which are placed in the field, There are many

animation links in the scada by which we can design the mimic of

components. So in one line the scada is the system by which we can see

the performance of the field component in our pc or our control room and

also change the value of control quantities by our pc from the control

room.


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- : Bibliography : -


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Study material by Futronix automation pvt. ltd.

Programmable logic by John. R . Hockwarth

controllers

Programmable logic by L.N.Bryan

controllers E.A.Bryan

Programmable logic by W.Batton

Controllers

Automatic manufacturing by Hugh Jack

System with PLC

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Documents

Futuronix Automation-Practical Training Report on Automation