Industrial Automation Summer Training Report, PLC, SCADA, HMI Instrumentation---shamsher

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Project Report on Industrial AutomationPLC, SCADA, HMI, INSTRUMENTATION.


<p>Project Report on Industrial Automation</p> <p>Submitted in partial fulfillment of the Requirement for the degree of Bachelor of TechnologyinMechanical Engineering</p> <p>Under Guidance of:</p> <p> Submitted By:</p> <p>Mr. Praveen Chugh Md.Shamsher Ansari(Associate Professor) 93059 ME-A (8th SEM)</p> <p>Session 2009-2013Department of Mechanical Engineering</p> <p>Shri Ram College of Engineering &amp; Management, Palwal</p> <p>Affiliated to Maharishi Dayanand University, Rohtak (Haryana).</p> <p>Declaration of Originality and Compliance of Academics Ethics</p> <p>I/We hereby declare that this project will contain literature survey and original work by undersigned candidate/candidates, as part of their B.Tech (Mechanical) studies.</p> <p>All Information for the project will be obtained and presented in accordance with academic rules and ethical conduct.</p> <p>I/We also declare that, as required by these rules and conduct, I/We will be fully cited and referenced all material and results that are not original to this work.</p> <p>(Signature of on the job guide with date)</p> <p>(Signature of Students with date)</p> <p> Mr. Praveen Chugh</p> <p> Md.Shamsher Ansari (Training Guide) 93059 2</p> <p>Certificate This training report is a genuine works by Mr. Md Shamsher Ansari, final yr, from Shri Ram college of engg &amp; mangt. 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.</p> <p> I wish her successful in all her future endeavors.Mr. Surinder Kumar </p> <p>Md Shamsher Ansari(HOD Mechanical)</p> <p> 930559</p> <p> ME-A (8th SEM)</p> <p> 3</p> <p>Acknowledgment</p> <p>I am thankful to the Institute Prolific for providing necessary facility to carry out my training successfully. Id also like to thank Er. Arun sing(M.E) and Er. Miss lofa (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 Who provided me such a great opportunity to do my summer training in a reputed institute like. Prolific Systems &amp; technologies</p> <p> ISO 9001-2008 Certified CompanyMr. Praveen Chugh</p> <p>Md. Shamsher Ansari(Internal Guide)</p> <p> 93059</p> <p> ME-A (8th SEM) 4PREFACEIt gives me an immense pleasure to submit this report as a part of practical training of 4 Months .Practical training is the most important part of the engineering studies.</p> <p>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,</p> <p>Introduction, quality policy and description op PLC, SCADA, HMI, instrumentations</p> <p> Md Shamsher Ansari</p> <p> 93059 </p> <p> ME-A (8th SEM) </p> <p> 5</p> <p> 6 Table of Content</p> <p>S.NoParticularsPage No.</p> <p>1.Abbreviation7</p> <p>2.Automation</p> <p>Introduction8 </p> <p>Example of automation8 to 9</p> <p>Types of automation, industrial automation10 to 13</p> <p>3.Programmable logic controller PLC</p> <p>Introduction, Relay13</p> <p>History of PLC, Advantages14 to 15</p> <p>Inside PLC, CPU, RAM, ROM, EEPROM, I/P Module16 to 17</p> <p>Output Module. Sensor, Actuator 18 to 19</p> <p> Number system, decimal, binary19 to 20</p> <p>Converting binary to decimal, Bits, byte words.logic1, logic021 to 22</p> <p>BCD, Hexadecimal, communication23 to 24</p> <p>PLC operation, Programming PLC, Ladder logic, Example24 to 30</p> <p>4.SCADA</p> <p>Introduction31</p> <p>System concept32</p> <p>Tags, types of Tags, classification of tags32 to 33</p> <p>Alarm, System components, Salient features34 to 35</p> <p>Benefits SCADA/HMI, Recommend 35</p> <p>5. HMI</p> <p>Introduction, types, difference between35 to 36</p> <p>6.Instrumentation, Application of automation, plc SCADA37 to 39</p> <p>7.Conclusion40</p> <p>8.References41</p> <p>9.Bibliography 42</p> <p>General Abbreviation</p> <p>PLC: Programmable logic controllers.</p> <p>SCADA: Supervisory control and data acquisition.</p> <p>I/P: Input</p> <p>O/P: Output.</p> <p>T-On: On timer.</p> <p>T-Off: Off timer.</p> <p>M: Memory Bits.</p> <p>Q: Output in program.</p> <p>MW: Memory words.</p> <p>NO: Normally open.</p> <p>NC: Normally closed.</p> <p>DCS: Distributed Control System.</p> <p>HMI: Human machine interference.</p> <p>VFD: Variable Frequency Drive.</p> <p>MD: Memory Double Word.</p> <p>MB: Memory Byte</p> <p>XIC: Examine If Closed</p> <p>XIO: Examine If Open</p> <p> 7AUTOMATION IntroductionAutomation is the use of control system such as computers to control industrial machinery &amp; process, reducing for need for human intervention. In the scope of industrialization,</p> <p>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.</p> <p> In other words </p> <p>Automation is a delegation of human control function to technical equipment for increasing productivity, to better quality, to reduce cost &amp; increase in safety working condition, to reduce manpower. </p> <p>Example of automation </p> <p> Automatic machine tools to process parts- CNC m/c Industrial robots Automatic material handling Feedback control system 8EXAMPLE OF AUTOMATION Automatic Material Handling Conveyors. Industrial Robots feedback control systems 9TYPES OF AUTOMATION Fixed automaton </p> <p> Programmable automation </p> <p> Flexible automationFixed automation</p> <p>Fixed automation refers to the use of custom-engineered (special purpose) equipment to automated 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.Programmable automation</p> <p>In programmable automation, the equipment is designed to accommodated a specific class of product changes and the processing or assembly operation can be changed by modifying the control program.</p> <p>Flexible automation</p> <p>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 manufacture various combination of products according to any specified schedule.INDUSTRIAL AUTOMATIONPLANT</p> <p> Monitoring &amp; controller</p> <p>Field instrument</p> <p>Intelligent controller</p> <p> 10Field instrument This type of instrument mainly used to get the feedback any type of process carried our so they mainly plant used Sensors, Transducer, Transmitter Proximity Sensor.</p> <p>Intelligent controller </p> <p>This device are basically micro control based or micro controller device mainly intelligent controller are:</p> <p> Programmable logic controller (PLC)</p> <p> PID Controller </p> <p> Distributed controller system (DCS)</p> <p> Computer Numerical controller (CNCPLC 11 PID</p> <p>CNC MACHINEMonitoring and controller </p> <p>This type of device to control whole plant just in a setting in control room, so mainly control device are Supervisory Control &amp; Data Acquisition (SCADA)</p> <p> Human Machine interface (HMI) 12 600 Series touch screen HMI.PROGRAMMABLE LOGIC CONROLLER IntroductionA 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 </p> <p>ever increasing sophistication and complexity of modern processing equipment requires faster acting, more reliable functions that electromechanical relays or timing devices cant offer.</p> <p>What is relay?</p> <p>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 13HISTORY OF PLC The first programmable logic controller were designed and developed by Modicon as a relay replacer for GM and landis.</p> <p> This controller eliminated the need for rewiring and adding additional for each new configuration of logics.</p> <p> The new system drastically increased the functionality of the control while reducing the cabinet space that housed the logic.</p> <p> The first PLC, model 084, was invented by Dick Morley in 1969.</p> <p> 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.</p> <p>Some of the additional advantages of PLCs are as follow</p> <p> Smaller physical size than hard-wire solutions</p> <p> Easier and faster and to make changes.</p> <p> PLCs have integrated diagnostics and override functions</p> <p> Diagnostics are centrally available </p> <p> Application can be immediately documented </p> <p> 14 Application can be duplicated faster and less expansively </p> <p> Speed in operation</p> <p> Security </p> <p> Online/ offline modifications </p> <p>PhotographshowingseveralinputandoutputmodulesofasingleAllen-Bradley PLC. 15INSIDE PLCThe Central processing Unit (CPU), contains and internal program that tells the PLCs how to perform the following functions:</p> <p> Execute the control instructions contained in the users</p> <p>Programs. This program is store in nonvolatile memory,</p> <p>Meaning that the program will not be lost if power is removed.</p> <p> Communicate with other device, which can include I/O</p> <p>Device, programming device, networks and even other PLCs</p> <p> Performs housekeeping activities such as communication, internal diagnostic, etc.</p> <p>THE CPU</p> <p>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. Todays processors vary widely in their capabilities to control the real world devices. Some control as few as 6 inputs andoutputs (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. RAMRAM 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 users program (ladder logic diagrams) and storage memory. 16ROM ROM or Read only memory is a non volatile memory. This means you dont 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.EEPROMEEPROM 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 t...</p>