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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?
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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
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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
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%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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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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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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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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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
25