PLC SCADA Training Report

[PLC , SCADA & AUTOMATION REPORT]
A SUMMER TRAINING REPORT

On
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PLC-SCADA AND AUTOMATION
Submitted in partial fulfilment of requirements for the award of
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Bachelors of Technology
In
Electrical and Electronics Engineering
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2012-2016
Submitted To
Er. PAWAN PUNIA-HOD,EEE
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Submitted By
JASKAWAL SINGH-12ETSEX009
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Saraf Institute of Engineering & Technology

Hanumangarh, Rajasthan
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CERTIFICATE
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ABSTRACT
An Industrial SCADA and PLC system is used for the development

of the controls of machinery. This report describes the SCADA &
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PLC systems in term of their architecture, their interface to the
process hardware, the functionality and the application
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development facilities they provide.
Some attention is also paid to the industrial standards to which

they abide their planned evolution as well as the potential benefits
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of their use.
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CANDIDATES DECLARATION
I hereby declare that the work presented in this report entitled

PLC-SCADA & Automation, submitted in EEE Department of
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Saraf Institute of Engineering and Technology, affiliated to
Rajasthan Technical University, Rajasthan, is an authentic record

of my own work carried out during my degree under the guidance
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of Er. Pawan Punia (HOD, EEE Deptt.)
The work reported in this has not been submitted by me for award
of any other degree or diploma.
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Signature of Candidate:
Jaskawal singh
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12ETSEX009
This is to certify that the above
statement made by the candidate is correct to the best of my
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knowledge.
Er. Pawan Punia (HOD,EEE Deptt.)
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ACKNOWLEDGEMENT
It gives me immense pleasure to express my deepest sense of

gratitude and sincere thanks to my highly respected and esteemed
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guide Er. Pawan Punia (HOD EEE Deptt.) S.I.E.T, Hanumangarh
for their valuable guidance, encouragement and help for

completing this work. Their useful suggestions for this whole work
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and co-operative behavior are sincerely acknowledged.
I would like to express my sincere thank to Mr. Manoj Sharma,

Founder, C.E.O & C.T.O ,Kaizen Robeonics Research Pvt. Ltd. for
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giving me this opportunity to undertake this training.
At the end I would like to express my sincere thanks to all my

friends and others who helped
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me directly or indirectly during this project work.
TABLE OF CONTENTS
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CHAPTER NO.
TITLE
PAGE NO.
TITLE PAGE........................................i
CERTIFICATE....................................ii
ABSTRACT..........................................iii
PAGE
CANDIDATES DECLARATION....iv
ACKNOWLEDGEMENT...................v
TABLE OF CONTENTS....................vi
LIST OF FIGURES.............................ix
PAGE
LIST OF TABLES................................x
PAGE
PAGE
1.
AUTOMATION....................................11
PAGE
1.1
1.2
1.3
1.4
1.5
1.6
Introduction to automation.....................12
Block diagram of automation.................14
Application.............................................14
Advantage and Disadvantage.................18
Automation tools....................................20
Limitation of automation........................21
2.
CONTROLLER.....................................22
2.1
2.2
PAGE
What are Controllers.............................23

Types of Controllers.............................23
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CHAPTER NO.
TITLE
PAGE NO.
2.
2.2.1 PID Controllers..................................23

2.2.2 CNC Controller..................................25
2.2.3 PC based Controller..........................27
2.2.4 PLC based Controller.......................29
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2.2.5 DCS..................................................30
3.
PLC....................................................... 31
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3.1 Introduction to PLC..............................32

3.2 History and Origin................................35
3.3 PLC Vendors.........................................36
3.4 Block diagram.......................................37
3.5 Major components of a PLC................37
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3.6 Classification of PLC............................38

3.7 PLC operation.......................................39
3.8 Scan Cycle.............................................39
3.9 Circuit isolation in PLC.........................41
3.10 Sinking and Sourcing concept.............43
3.11 Communications..................................43
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3.12
3.13
3.14
3.15
3.16
3.17
Programming Language......................46.
Ladder logic .......................................47
Timers ................................................49
Compare instructions..........................50
Counter................................................52
Compute/Math ...................................53
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3.18 Move/Logical .....................................54

3.19 Softwares.............................................56
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CHAPTER NO.
TITLE
PAGE NO.
4.
SCADA.....................................................59
4.1 Introduction to SCADA...............................60
4.2 What SCADA can do for you......................61
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4.3 SCADA software.........................................62
4.4 Functionality...............................................63
4.5 Automation.................................................70
4.6 Application Development...........................71
4.7 Application of SCADA...............................72
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4.8 Communication ..........................................76
CONCLUSION....................................77
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REFERENCES....................................78
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LIST OF FIGURES
S NO.
PAGE
1.
2.
3.
4.
NAME
PAGE NO.
Block Diagram of Automation.................14

Block diagram of PID Controller...............25
Computer Numerically Controlled.............27
Allen Bradley PLC....................................32
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5.
6.
7.
8.
9.
10.
Block diagram of PLC...............................37

Scan Cycle of a PLC..................................40
Circuit Diagram of PLC.............................42
Sinking and Sourcing Concept...................43
Ethernet Cable............................................44
PMO2 Cable...............................................45
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11.
12.
13.
14.
Trending.....................................................64
Alarm Handling..........................................65
Logging and Archiving...............................66
SCADA Systems........................................75
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LIST OF TABLES
S NO.
NAME
PAGE NO.
PLC Vendors.........................................36
2.
Allen Bradley Data File Description.....57
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1.
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Chapter - I
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Automation
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1.1 Introduction to Automation
Automation is the use of control systems such as computers to

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control industrial machinery and processes, reducing the need for
human intervention. In the scope of industrialization, automation

is a step beyond mechanization. Whereas mechanization provided
human operators with machinery to assist them with the physical
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requirements of work, automation greatly reduces the need for
human sensory and mental requirements as well. AutomationIs

Basically The Use Of Control Systems (Such As Numerical
Control, Programmable Logic Control, And Other Industrial
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Control Systems), In Concert With Other Applications Of
Information Technology (Such As Computer-Aided Technologies

[CAD, CM, Cax]), To Control Industrial Machinery And
Processes, Reducing The Need For Human Intervention. In The
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Scope Of Industrialization, Automation Is A Step Beyond
Mechanization.
Whereas
Mechanization
Provided
Human
Operators With Machinery To Assist Them With The Muscular
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Requirements Of Work, Automation Greatly
reduces The Need For Human Sensory And Mental

Requirements As Well. Processes And Systems Can Also Be
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Automated.
Automation Plays An Increasingly Important Role In The

Global Economy And In Daily Experience. Engineers Strive To
Combine
Automated
Devices
With
Mathematical
And
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Organizational Tools To Create Complex Systems For A Rapidly
Expanding Range Of Applications And Human Activities.

Specialized Hardened Computers, Referred To As Programmable
Logic Controllers (Plcs), Are Frequently Used To Synchronize The
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Flow Of Inputs From (Physical) Sensors And Events With The
Flow Of Outputs To Actuators And Events. This Leads To

Precisely Controlled Actions That Permit A Tight Control Of
Almost Any Industrial Process. Human-Machine Interfaces
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(HMI) Or Computer Human Interfaces (CHI), Formerly Known
As
Man-MachineInterfaces,
Are
Usually
Employed
To
Communicate With Plcs And Other Computers, Such As Entering

And Monitoring Temperatures Or Pressures For Further
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Automated Control Or Emergency Response.
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1.2. Block diagram of automation
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FIG:01
1.3. Applications
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Automated video surveillance:
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The Defense Advanced Research Projects Agency (DARPA)

started the research and development of automated visual
surveillance and monitoring (VSAM) program, between 1997
and 1999, and airborne video surveillance (AVS) programs,
from 1998 to 2002. Currently, there is a major effort
underway in the vision community to develop a fully
automated tracking surveillance system. Automated video

surveillance
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monitors people and vehicles in real time within a busy

environment. Existing automated surveillance systems are
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based on the environment they are primarily designed to

observe, i.e., indoor, outdoor or airborne, the amount of
sensors that the automated system can handle and the
mobility of sensor, i.e., stationary camera vs. mobile camera.
The purpose of a surveillance system is to record properties
and trajectories of objects in a given area, generate warnings
or notify designated authority in case of occurrence of
Automated highway systems:
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As demands for safety and mobility have grown and

technological possibilities have multiplied, interest in
automation has grown. Seeking to accelerate the development
and introduction of fully automated vehicles and highways,
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the United States Congress authorized more than $650

million over six years for intelligent transport systems (ITS)
and demonstration projects in the 1991Intermodal Surface
Transportation Efficiency Act (ISTEA). Congress legislated in
ISTEA that the Secretary of Transportation shall develop an
automated highway and vehicle prototype from which future
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fully automated intelligent vehicle-highway systems can be

developed. Such development shall include research in
human factors to ensure the success of the man-machine
relationship. The goal of this program is to have the first fully
automated highway roadway or an automated test track in
operation by 1997. This system

installation of equipment in new and
shall
accommodate
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existing motor vehicles.Full automation commonly defined as

requiring no control or very limited control by the driver;
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such automation would be accomplished through a

combination of sensor, computer, and communications
systems in vehicles and along the roadway. Fully automated
driving would, in theory, allow closer vehicle spacing and
higher speeds, which could enhance traffic capacity in places
where additional road building is physically impossible,
politically unacceptable, or prohibitively expensive.
Automated manufacturing:
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Automated manufacturing refers to the application of

automation to produce things in the factory way. Most of the
advantages of the automation technology has its influence in
the manufacture processes.
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The main advantages of automated manufacturing are higher

consistency and quality, reduced lead times, simplified
production, reduced handling, improved work flow, and
increased worker morale when a good implementation of the
automation is made.
Home automation:
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Home automation (also called domotics) designates an

emerging practice of increased automation of
household
appliances and features in residential dwellings, particularly
through electronic means that allow for things impracticable,

overly expensive or simply not possible in recent past decades.
Industrial automation:
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Industrial automation deals with the optimization of energyefficient drive systems by precise measurement and control
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technologies. Nowadays energy efficiency in industrial

processes are becoming more and more relevant.
Semiconductor companies like Infineon Technologies are
offering 8-bit microcontroller applications for example found
in motor controls, general purpose pumps, fans, and ebikes to
reduce energy consumption and thus increase efficiency.
Agent-assisted Automation :
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Agent-assisted Automation refers to automation used by call

center agents to handle customer inquiries. There are two
basic types: desktop automation and automated voice
solutions. Desktop automation refers to software
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programming that makes it easier for the call center agent to

work across multiple desktop tools. The automation would
take the information entered into one tool and populate it
across the others so it did not have to be entered more than
once, for example. Automated voice solutions allow the agents
to remain on the line while
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disclosures and other important information is provided to

customers in the form of pre-recorded audio files. Specialized
applications of these automated voice solutions enable the
agents to process credit cards without ever seeing or hearing
the credit card numbers or CVV codes.
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The key benefit of agent-assisted automation is compliance

and error-proofing. Agents are sometimes not fully trained or
they forget or ignore key steps in the process. The use of
automation ensures that what is supposed to happen on the
call actually does, every time.
1.4. Advantages
The main advantages of automation are:
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Increased throughput or productivity.
Improved quality or increased predictability of quality.
Improved robustness (consistency), of processes or

product.
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The following methods are often employed to improve productivity,

quality, or robustness.
Install automation in operations to reduce cycle time.
Install automation where a high degree of accuracy is

required.
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Replacing human operators in tasks that involve hard

physical or monotonous work.[3]
Replacing humans in tasks done in dangerous environments

(i.e. fire, space, volcanoes, nuclear facilities, underwater, etc.)
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Performing tasks that are beyond human capabilities of size,

weight, speed, endurance, etc.
Economy improvement: Automation may improve in economy

of enterprises, society or most of humanity. For example, when
an enterprise invests in automation, technology recovers its
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investment; or when a state or country increases its income due

to automation like Germany or Japan in the 20th Century.
Reduces operation time and work handling time significantly.
Frees up workers to take on other roles.

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Provides higher level jobs in the development, deployment,

maintenance and running of the automated processes.
Disadvantages
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The main disadvantages of automation are:
Security Threats/Vulnerability: An automated system

may have a limited level of intelligence, and is therefore more
susceptible to committing errors outside of its immediate
scope of knowledge (e.g., it is typically unable to apply the
rules of simple logic to general propositions).
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Unpredictable/excessive development costs: The research

and development cost of automating a process may exceed the
cost saved by the automation itself.
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High
initial
cost:
The
automation
of
a
new product or plant typically requires a very large initial
investment in comparison with the unit cost of the product,
although the cost of automation may be spread among many
products and over time.
1.5. Automation tools
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Engineers can now have numerical control over automated

devices. The result has been a rapidly expanding range of
applications
and
human
activities. Computer-aided
technologies (or CAx) now serve the basis for mathematical and
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organizational tools used to create complex systems. Notable

examples of CAx include Computer-aided design (CAD software)
and Computer-aided manufacturing (CAM software). The
improved design, analysis, and manufacture of products enabled
by CAx has been beneficial for industry.
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Information
technology,
together
with industrial machinery and processes, can assist in the design,
implementation, and monitoring of control systems. One example
of an industrial control system is a programmable logic
controller (PLC). PLCs are specialized hardened computers which
are frequently used to synchronize the flow of inputs from
(physical) sensors and events with the flow of outputs to actuators

and events.
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An automated online assistant on a website, with an avatar for

enhanced human.
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Human-machine
interfaces (HMI)
or computer
human
interfaces (CHI), formerly known as man-machine interfaces, are
usually employed to communicate with PLCs and other
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computers. Service personnel who monitor and control through

HMIs can be called by different names. In industrial process and
manufacturing environments, they are called operators or
something similar. In boiler houses and central utilities
departments they are called stationary engineers.
Different types of automation tools exist:

DCS - Distributed Control System
HMI - Human Machine Interface
SCADA - Supervisory Control and Data Acquisition

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PLC - Programmable Logic Controller
Instrumentation
Motion control
Robotics
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1.6. Limitations to automation

Current technology is unable to automate all the desired
tasks.
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As a process becomes increasingly automated, there is less

and less labor to be saved or quality improvement to be gained.
This is an example of both diminishing returns and the logistic
function.
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Similar to the above, as more and more processes become

automated, there are fewer remaining non-automated processes.
This is an example of exhaustion of opportunities.
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Chapter II
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Controllers
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2.1. What Are Controllers?
In control theory, a controller is a device which monitors and

affects the operational conditions of a given dynamical system.
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The operational conditions are typically referred to as output
variables of the system which can be affected by adjusting certain

input variables.
For example, the heating system of a house can be equipped
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with a thermostat (controller) for sensing air temperature (output
variable) which can turn on or off a furnace or heater when the

air temperature becomes too low or too high.
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2.2. TYPES OF CONTROLLERS
There are many types of controllers. Some of them are as follows:
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2.2.1 PID Controllers
A proportionalintegralderivative controller (PID controller) is a

generic control loop feedback mechanism (controller) widely used
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in industrial control systems.
PID controller attempts to correct the error between a

measured process variable and a desired set point by calculating
and then outputting a corrective action that can adjust the process
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accordingly and rapidly, to keep the error minimal.
The PID controller calculation (algorithm) involves three

separate parameters; the proportional, the integral and derivative
values. The proportional value determines the reaction to the
current error, the integral value determines the reaction based on
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the sum of recent errors, and the derivative value determines the
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PAGE
FIG:
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2.2.2 Computer Numerically Controlled (CNC)
Computer Numerical Control (CNC) controllers, working as a

brain for manufacturing automation, are high value-added
products counting for over 30% of the price of machine tools.
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CNC technology is generally considered as a measure for the level
of manufacturing technology of a nation. Often referred to as

"The Flower of Industrial Technology", the development of CNC
technology depends upon the integration of technologies from
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computer, hardware, machining, and other industries, and
requires strategic long-term support, mostly on a governmental
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level.
Today, computer numerical control (CNC) machines are found

almost everywhere, from small job shops in rural communities to
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Fortune 500 companies in large urban areas. Truly, there is hardly
a facet of manufacturing that is not in some way touched by what

these innovative machine tools can do.
The most basic function of any CNC machine is automatic,
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precise, and consistent motion control. Rather than applying
completely mechanical devices to cause motion as is required on

most conventional machine tools, CNC machines allow motion
control in a revolutionary manner. All forms of CNC equipment
PAGE
have two or more directions of motion, called axes. These axes can
be precisely and automatically positioned along their lengths of

travel. The two most common axis types are linear (driven along a
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straight path) and rotary (driven along a circular path).
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PAGE
FIG:03
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2.2.3 PC Based Controllers
The days of the PC being used just for visualization and

production
data
acquisition
in
control
and
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applications is rapidly becoming a thing of the past.
automation
The PC is now increasingly recognized as an open and

powerful hardware platform, which can provide effective and
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reliable control, with no requirement for additional processors
or complex hardware additions. Traditional automation and

control systems typically comprise a number of hardware and
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software elements; a PC for process visualization, hard PLCs with
coprocessor cards, coprocessor PLCs, I/O via field bus, motion

control via parallel cabling and a selection of software operating
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systems and programming languages.
PC-based controller system is often used in the factory where

it resists the adverse environmental factors such as dustiness and
extreme temperature. Under this condition, PC-based controller
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system must meet the requirements of reliability, durability, strong
vibration, and extreme temperature. Since industrial products do

not require high level of math functions, appropriateness is much
more important than the performance.PC-based system is also
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used in the medical care industry.
The disadvantages of this approach being high hardware and

software costs, complexity of system design and build plus, in
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many applications, limited functionality.
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2.2.4 Programmable Logic Controllers (PLC)
Programming Logic Controller or PLC as it is universally called is
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the work horse of industrial automation. The PLC,
being a microprocessor based device, has a similar internal

structure to many embedded controllers and computers. They
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consist of the CPU, Memory and I/O devices. These components
are integral to the PLC controller. Additionally the PLC has a

connection for the Programming and Monitoring Unit, Printer
and Program Recorder.
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Basically PLC is used for following applications in industry:
1) Machine controls.
2) Packaging, loading uploading and weighing.

3) Palletizing.
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4) Material handling and similar Sequential task
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2.2.5 Distributed Control System (Dcs)
A distributed control system (DCS) refers to a control system

usually of a manufacturing system, process or any kind of
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dynamic system, in which the controller elements are not central
in location (like the brain) but are distributed throughout the

system with each component sub-system controlled by one or more
controllers. The entire systems of controllers are connected by a
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network for communication and monitoring.
DCS is a very broad term used in a variety of industries, to monitor

and control distributed equipment like Electrical power grids and
electrical generation plants, Environmental control systems,
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Traffic, water management systems, Oil Refining plants, chemical,
Pharmaceutical manufacturing, Dry cargo and bulk oil carrier

ships.Distributed control systems (DCS) use decentralized elements
or subsystems to control distributed processes or complete
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manufacturing systems.
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Chapter III
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Programmable Logic Controller

(PLC)
3.1. Introduction to PLC
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A PLC is an industrial computer or control system that

continuously monitors the state of input devices and makes
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decisions based upon a custom program to control the state of
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output devices.
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FIG:04
A programmable logic controller (PLC) or programmable

controller
is
digital
computer
used
for
automationof
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electromechanical processes, such as control of machinery on
factory aassembly lines, amusement rides, or lighting fixtures.

PLCs are used in many industries and machines. Unlike general-
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purpose computers, the PLC is designed for multiple
inputs and output arrangements, extended temperaure ranges,

immunity to electrical noise, and resistance to vibration and
impact. Programs to control machine operation are typically stored
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in battery-backed or non-volatile memory. A PLC is an example of
a real time system since output results must be produced in

response to input conditions within a bounded time, otherwise
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unintended operation will result.
A PLC (i.e. Programmable Logic Controller) is a device that was

invented to replace the necessary sequential relay circuits for
machine control. The PLC works by looking at its inputs and
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depending upon their state, turning on/off its outputs. The user
enters a program, usually via software, that gives the desired

results.
PLCs are used in many "real world" applications. If there is
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industry present, chances are good that there is a plc present. If
you are involved in machining, packaging, material handling,

automated assembly or countless other industries you are probably
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already using them. If you are not, you are wasting money and
time. Almost any application that needs some type of electrical
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control has a need for a plc.
PLC controllers are low cost, compact, versatile units based on the
standard microprocessor architecture used in the control of
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machines or processes. They are designed for ease of
programming and maintenance. The plc systems replace the old

relay logic control systems in automated manufacturing and are
designed to provide an easy and efficient replacements for the
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bulky relay logic controllers. The PLC, also known as
programmable controller (PC) is defined by the National

Electrical Manufacturers Association (NEMA) in 1978 as:
"A digitally operating electronic apparatus which uses a
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programmable memory for the internal storage of instructions for
implementing specific functions, such as logic, sequencing, timing,

counting and arithmetic, to control through digital or analog
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input/output, various types of machines or process".
They essentially operate by detecting the on/off (logic) or analog

inputs and depending on the control programs - the ladder
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diagrams - outputs of the same type (usually logic) are produced.
In PLC implementation, field wiring between the logic elements

remains unaltered, but there are no more hard wired connections
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between the devices. Instead, the connections are
stored in computer memory. This allows the programming of these

connections, which is in turn made easier as they are entered in
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ladder logic.
PLC systems have considerable advantages over the old relay logic
systems. They include:
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1 all the capabilities of the earlier systems,
2 dramatic performance increase over the relay logic systems

3 greater reliability
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4 little maintenance due to no moving parts
5 no special programming skills required by maintenance

personnel
6 physical size of the PLC system is much smaller than the
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conventional relay based logic
7 and most importantly much lower cost
3.2. History and Origin

PAGE
Developed to replace relays in the late 1960s
PLC began in the 1970s, and has become the most common
choice for manufacturing controls.
The first PLC, model 084, was invented by Dick Morley.
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The PLC was invented in response to the needs of the

American automotive manufacturing industry (primarily
General motors).
Costs dropped and became popular by 1980s
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Now used in many industrial designs.
3.3. PLC Vendors
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S.N
Company
Country
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3.4. Block Diagram of PLC
PAGE
FIG:05
3.5. Major Components of a Common PLC

POWER SUPPLY
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Provides the voltage needed to run the primary PLC components.
I/O MODULES
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Provides signal conversion and isolation between the internal

logiclevel signals inside the PLC and the fields high level
signal. The I/O interface section of a PLC connects it to external
field devices. The main purpose of the I/O interface is to condition
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the various signals received from or sent to the external input and
output devices. Input modules converts signals from discrete or
analog input devices to logic levels
acceptable to PLCs processor. Output modules converts signal

from the processor to levels capable of driving the connected
discrete or analog output devices.
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PROCESSOR
Provides intelligence to command and govern the activities of the

entire PLC systems.
PROGRAMMING DEVICE
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Used to enter the desired program that will determine the sequence
of operation and control of process equipment or driven machine.
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3.6. CLASSIFICATION OF PLC
Based on physical assembly-
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1. Compact - In these types of PLC the number of input and output

is fixed and these are very purpose specified.
2. Modular - In this type of PLC the input and output modules are
used and thus the number of the I/O ports is variable n depend
upon the number of slots available and modules used.
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Based on number of I/O ports-
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1. Small-It covers units with up to 128 I/Os and memories up to 2

Kbytes.
These PLCs are capable of providing simple to advance
levels or machine controls.
2. Medium- has up to 2048 I/Os and memories up to 32 Kbytes.
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3. Large- the most sophisticated units of the PLC family. They

have up to 8192 I/Os and memories up to 750 Kbytes. can control
individual production processes or entire plant.
3.7. PLC Operation
Basic Function of a Typical PLC
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Read all field input devices via the input interfaces, execute the
user program stored in application memory, then, based on
whatever control scheme has been programmed by the user, turn
the field output devices on or off, or perform whatever control is

necessary for the process application.
PAGE
This process of sequentially reading the inputs, executing the

program in memory, and updating the outputs is known as
scanning.
3.8. Scan Cycle
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While the PLC is running, the scanning process includes the

following three phases, which are repeated continuously as
individual cycles of operation
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PAGE
PAGE
FIG:06
PHASE 1 Input Status scan
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A PLC scan cycle begins with the CPU reading the status of its
inputs.
PHASE 2 Logic Solve/Program Execution
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The application program is executed using the status of the inputs.
PHASE 3 Output Status Scan
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An output status scan is then performed, whereby the stored output

values are sent to field output devices. The cycle ends byupdating
the outputs. As soon as Phase 3 are completed, the entire cycle
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begins again with Phase 1 input scan. The time it takes to

implement a scan cycle is called SCAN TIME. The scan time
composed of the program scan time, which is the time required for
solving the control program, and the I/O update time, or time
required to read inputs and update outputs. The program scan
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time generally depends on the amount of memory taken by the

control program and type of instructions used in the program. The
time to make a single scan can vary from 1 ms to 100 ms.
3.9. Circuit Isolation in PLC
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In PLC, isolation is provided using optocoupler in its internal

circuit thats why it is also known as optical isolation. Optical
isolation means that there is no real electrical connection between
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the input device and the processor. This eliminates any possibility
of the unwanted (high surge or malfunctioned) input line voltage
from coming in contact with and damaging the low voltage DC
section of the Processor.
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PAGE
FIG:07
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3.10. Sinking and sourcing concept
Sinking Concept (NPN)- When the current direction of

any signal is inwards to the PLC input or output port it is
known as the Sinking.
PAGE
Sourcing Concept (PNP) - When the current direction of

any signal is outwards to the PLC input or output port it is
known as the Sourcing ..
PAGE
PAGE
FIG:08
3.11. Communications :
PAGE
PLC can communicate or connected to PC through Ethernet,RS232,RS-422 or RS-485 cabling.
PAGE
Ethernet
PAGE
Ethernet introduced in 1980.Ethernet divide a stream of data into

individual packets called frames. Each frame contains source &
destination address & error checking data so that damaged data
can be detected & re-transmitted. Data rates were periodically
PAGE
increased from the original 10 megabits per sec to 100 gigabits per
sec
PAGE
FIG:09 Ethernet cable
RS-232
PAGE
It can transfer-20000 bits per second. It is commonly used in

computer for serial port RS-232 port has feature of a personal
PAGE
computer for connected to modems,printer,mice,UPS & other

peripheral device. PM02 cable is used for this type of
communiction.it has 9 pin on PC side and 8 pin on PLC side.
PAGE
PAGE
FIG:10 PM02 cable
PAGE
RS-485
RS-485 can be used effectively over long distances. it can transfer35M bits per second up to 10 meter 100 Kbits/sec 1200 meter.
PAGE
RS-422
PAGE
It can transfer-10 Million bits per second. It can used as long as

1500 meter.
3.12. Programming Languages

Ladder Diagram (LD)
Functional block Diagram (FBD)
PAGE
Sequential Functional Chart (SFC)
Structured Text (ST)
Instruction List (IL)
PAGE
Ladder Diagram- It is a graphical programming language.
PAGE
Initially programmed with simple contacts that simulated the

opening and closing of relays, Ladder Logic Programming has
been expanded to include such functions as counters, timers, shift
registers, and math operations.
Function Block Diagram A graphical language for depicting
PAGE
signal and data flows through re-usable function blocks. FBD is

useful for expressing the interconnection of control system
algorithms and logic.
Sequential Function Chart A method of programming
PAGE
complex control systems at a more highly structured level. A SFC

program is an overview of the control system, in which the basic
building blocks are entire program files. Each program file is
created using one of the other types of programming languages.
The SFC approach coordinates large, complicated programming

tasks into smaller, more manageable tasks.
Structured Text A high level text language that encourages
PAGE
structured programming. It has a language structure (syntax)
that strongly resembles PASCAL and supports a wide range of

standard functions and operators.
Instruction List A low level assembler like language that is
PAGE
based on similar instructions list languages found in a wide range

of todays PLC.
The language which we used in the PLC for writing any logic is
Ladder language.
PAGE
3.13. Ladder Logic
PAGE
Ladder logic is a method of drawing electrical logic schematics. It

is now a graphical language very popular for programming
Programmable Logic Controllers (PLCs). It was originally
invented to describe logic made from relays. The name is based on
the observation that programs in this language resemble ladders,
with two vertical "rails" and a series of horizontal "rungs"

between them.
PAGE
Generally Used Instructions & symbol For PLC Programming
Input Instruction
PAGE
This Instruction is Called XIC or Examine If Closed.
i.e.; If a NO switch is actuated then only this instruction

will be true. If a NC switch is actuated then this
PAGE
instruction will not be true and hence output will not be generated.
This Instruction is Called XIO or Examine If Open
PAGE
i.e.; If a NC switch is actuated then only this instruction will

be true. If a NC switch is actuated then this instruction will not be
true and hence output will not be generated.
Output Instruction
PAGE
This Instruction is called OTE and shows the States of

Output.
i.e.; If any instruction either XIO or XIC is true then

output will be high. Due to high output a 24 volt signal is
generated from PLC processor.
PAGE
Retentive output instruction
PAGE
OTL (output latch):

If the rung is true, turns ON a bit and it remains ON even the rung
gets false. The bit stays ON until the rung containing an OUT with
same address goes true.
PAGE
OTU (output unlatch ):If the rung is true, turns OFF a bit. The bit
stays OFF until the rung containing an OTL with
PAGE
same address goes true and the rung containing OUT with same
address remains false.
3.14. Timers
PAGE
1. TON-
PAGE
This is an ON timer , in this we set the time base and can give the
time delay.
PAGE
2. TOF
PAGE
PAGE
This is an OFF timer, here we need to enable as well as disable the

timer.
PAGE
3. RTO-
This is called Retentive Timer On, here the timer is not reset once
we disable it, so we need to use the RES (reset) function. This
timer can be paused easily.
PAGE
3.15. Compare instructions:
PAGE
1. LIM (limit test):
PAGE
The Rung goes true when test value in between lower and higher
limit.
PAGE
2.EQU (Equal):
PAGE
The rung goes true, when source A equal to source B.
PAGE
3.NEQ (Not Equal):
PAGE
PAGE
4.LES (Less Than):
PAGE
5.GRT(Greater Than):
PAGE
6.LEQ( Less Than or Equal):
PAGE
7.GEQ( Greater Than or Equal):
PAGE
3.16. Counters
PAGE
1. CTU-
PAGE
This is Counter Up, here we set the preset and whenever the signal
is given the accumulator is increased, to reset the counter we have
to use RES.
PAGE
2. CTD-
PAGE
This is Counter down, here DN bit is on initially and as the

accumulator decreases and becomes less than preset it becomes
off.
PAGE
RESET Function-
This function is used to reset the counters and the timers.
PAGE
3.17. Compute / Math:
PAGE
1.ADD (Addition):
PAGE
When the rung goes true, value stored in source A is added with
value stored in Source B and the resulted value is stored in
Destination.
PAGE
2.SUB (Subtraction):
PAGE
PAGE
3.MUL (Multiplication):
PAGE
PAGE
4.DIV (Division):
PAGE
PAGE
5.SQR (Square Root):
3.18. Move/Logical:
PAGE
1. MOV (Move):
PAGE
PAGE
When rung goes true the value stored in source move to
destination.
PAGE
2.AND (Bitwise Logical AND):
PAGE
When the rung goes true, value stored in source

A is Logically ANDed with value stored in Source B and the
resulted value is stored in destination.
PAGE
3.OR (Bitwise Logical OR):
PAGE
PAGE
4.XOR (Bitwise Logical NOR):
PAGE
PAGE
PAGE
5.NOT(Bitwise Logical NOT):
PAGE
6.CLR(Clear):
When rung goes true, then destination becomes

PAGE
empty.
3.19. Software for PLC
PAGE
For Allen Bradley(Micro) :-
Simulator: - Logix Pro
Communication software: - Rslinx classic
PAGE
Programming software: Microstarter Lite
Rslogix500 OR Rslogix
PAGE
Allen Bradley Data File Description
File
Type
Description
#
O0
Output
This file stores the state of output
PAGE
terminals for the controller.
I1
Input
This file stores the state of input

terminals for the controller.
S2
Status
This file stores controller operation
PAGE
information useful for troubleshooting

controller and program operation.
PAGE
PAGE
PAGE
PAGE
Chapter IV
PAGE
SCADA
4.1. Introduction to SCADA

SCADA stands for supervisory control and data acquisition. As the
PAGE
name indicates it is not a full control system, but rather focuses on
the supervisory level. As such , it is a purely software package that

is positioned on the top of hardware to which it is interfaced in
general via programmable logic controllers (PLCs ), or other
PAGE
commercial hardware modules.
S- supervisory (we can see process on monitor)
C- control(when setup is complete we can also control the
PAGE
process )
A- and
D- data( database can also be saved in plc or pc memory)
PAGE
A- acquisition
SCADA programs are used in industrial process control

applications for centralized monitoring and recording of pumps,
PAGE
tank levels, switches, temperatures etc. SCADA systems are also
referred to as HMI (Human Machine Interfaces), or the less

politically correct MMI (Man Machine Interfaces).
A SCADA program normally runs on a PC and communicates
PAGE
with external instrumentation and control
devices. Communications methods can be via direct serial

link, radio, modem, field bus or Ethernet links. If a mixture of
PAGE
instruments with differing communication interfaces and protocols
need to be connected, then converters can be used. SCADA is often

used on remote data acquisition systems where the data is viewed
PAGE
and recorded centrally.
Its an optional device used in automation for continuous
PAGE
monitoring.
4.2. What SCADA can do for you:
PAGE
SCADA is not a specific technology, but a type of application.

SCADA stands for Supervisory
Control and Data Acquisition any application that gets data
about a system in order to control
PAGE
that system is a SCADA application.

A SCADA application has two elements:
1. The process/system/machinery you want to monitor a control
this can be a power
Plant, a water system, a network, a system of traffic lights, or
anything else.
PAGE
2. A network of intelligent devices that interfaces with the first

system through sensors and
Control outputs. This network, which is the SCADA system, gives
you the ability to
Measure and control specific elements of the first system.
A SCADA system usually consists of the following subsystems:
PAGE
1. Human-machine interface or HMI is the apparatus which

presents process data to a human operator, and through this, the
human operator, monitors and controls the process. A supervisory
(compute) system, gathering (acquiring) data on the process and
sending commands (control) to the process.
2. Remote terminal units(RTUs) connecting to sensors in the

process, converting sensor signals to digital data and sending
digital data to the supervisory system.
PAGE
3. Programmable logic controller (PLCs) used as field devices

because they are more economical, versatile, flexible, and
configurable than special-purpose RTUS.
Communication infrastructure connecting the supervisory system

to the remote terminal units.
PAGE
4.3. SCADA software:-
Allen Bradley RSView 32
PAGE
Wonder ware InTouch
PAGE
Siemens Win CC
4.4. Functionality
PAGE
4.4.1 Access Control
Users are allocated to groups, which have defined read/write

access privileges to the process parameters in the system and
often also to specific product functionality.
PAGE
4.4.2 Trending
The
products
all
provide
trending
facilities
and
one can summarize the common capabilities as follows:

1) the parameters to be trended in a specific chart can be
PAGE
predefined or defined online
2) A chart may contain more than 8 trended parameters or

pens and an unlimited number of charts can be displayed
(restricted only by the readability)
PAGE
3) Real-time and historical trending are possible, although
PAGE
generally not in the same chart
PAGE
PAGE
FIG:11
4) Historical trending is possible for any archived parameter

PAGE
5) Zooming and scrolling functions are provided
6) Parameter values at the cursor position can be displayed

The trending feature is either provided as a separate
module or as a graphical object (ActiveX), which can then be
PAGE
embedded into a synoptic display. XY and other statistical analysis
PAGE
plots are generally not provided.
4.4.3 Alarm Handling
Alarm handling is based on limit and status checking and

performed in the data servers. More complicated expressions
PAGE
(using arithmetic or logical expressions) can be developed by
creating derived parameters on which status or limit checking is

then performed. The alarms are logically handled centrally i.e.,
the information only exists in one place and all users see the
PAGE
same status (e.g., the acknowledgement), and multiple alarm
priority levels (in general many more than 3 such levels) are
PAGE
supported.
PAGE
PAGE
FIG:12
4.4.4 Logging And Archiving
The terms logging and archiving are often used to describe

the
same
facility.
However, logging can be thought of as
PAGE
medium-term storage of data on disk, whereas archiving is long-
term storage of data either on disk or on another permanent

storage medium. Logging is typically performed on a cyclic basis,
i.e., once a certain file size, time period or number of points is
PAGE
reached the data is overwritten. Logging of data can be performed
at a set frequency, or only initiated if the value changes or

when a specific predefined event occurs. Logged data can be
PAGE
transferred to an archive once the log is full.
PAGE
FIG:13
The Logged data is time-stamped and can be filtered when viewed

PAGE
by a user. The logging of user actions is in general performed
together with either a user ID or station ID. There is often also a

VCR facility to play back archived data.
PAGE
4.4.5 Networking
1. In many application, we have to use more than one SCADA

software / operator stations. This can be achieved by taking
the SCADA node on network.
PAGE
2. In many cases Ethernet TCP/IP is commonly used for
networking.
3. In certain cases the SCADA software use propriety
PAGE
networking protocols for networking.
4.4.6 Device Connectivity
1. Every control hardware has its own communication protocol

for communicating with different hadrware / software. Some
PAGE
of the leading communication protocol include Modbus,
Profibus, Ethernet, Dh +, DH 485, Devicenet, Control net
2. The SCADA software needs device driver software for
PAGE
communication with PLC or other control hardware.
3. More the driver software available better is the device

connectivity. Most of the SCADA software used in the
industry have connectivity with most of the leading control
PAGE
system.
4.4.7 Database Connectivity
PAGE
1. In many plants, it is important to download the real-time
information to the MIS. In this case the database connectivity

is must.
2. Many SCADA software dont have their own database. Hence
PAGE
for storage and reporting they use third party database like
PAGE
MS Access or SQL.
PAGE
4.4.8 Script
1. Script is a way of writing logic in SCADA software. Every

SCADA software has its own instructions and way of writing
PAGE
program.
2. Using scripts, one can develop complex applications. You can

create your own functions to suit the process requirement.
execution.
PAGE
3. Various types of scripts make project execution simpler for
programmer.
PAGE
4.4.9 Report Genertion
One can produce reports using SQL type queries to the archive,
RTDB or logs. Although it is sometimes possible to embed
EXCEL charts in the report, a "cut and paste" capability is in
PAGE
general not provided. Facilities exist to be able to automatically
PAGE
generate, print and archive reports.
4.5 AUTOMATION
The
majority
of
the
products
allow
actions
to
be
automatically triggered by events. A scripting language provided

PAGE
by the SCADA products allows these actions to be defined. In
general,
one
can
load
particular
display,
send
an
Email, run a user defined application or script and write to

the RTDB.
PAGE
The concept of recipes is supported, whereby a particular
system configuration can be saved to a file and then re-loaded at

a later date .Sequencing is also supported whereby, as the name
indicates, it is possible to execute a more complex sequence of
PAGE
actions on one or more devices. Sequences may also react to
external events. Some of the products do support an expert

system but none has the concept of a Finite rate Machine
PAGE
(FSM).
PAGE
4.6 Application Development
PAGE
4.6.1 Configuration
SCADA is not a specific technology, but a type of application.

SCADA stands for Supervisory Control and DataAcquisition
any application that gets data about a system in order to control
PAGE
that system is a SCADA application.
A SCADA application has two elements:
1 The process/system/machinery you want to monitor a control

this can be a power plant, a water system, a network, a system of
PAGE
traffic lights, or anything else.
2 A network of intelligent devices that interfaces with the first

system through sensors and control outputs. This network,
which is the SCADA system, gives you the ability to measure and
PAGE
control specific elements of the first system.
The development of the applications is typically done in

two
stages.
First the process parameters and associated
PAGE
information (e.g. relating to alarm conditions) are defined
through some sort of parameter definition template and

then the graphics, including trending and alarm displays are
developed, and linked where appropriate to the process
PAGE
parameters.
The
products
also
provide
an
ASCII
Export/Import
facility
for
the configuration data (parameter
definitions), which enables large numbers of parameters to be

configured in a more efficient manner using an external editor
PAGE
such as Excel and then importing the data into the configuration
database.
On-line modifications to the configuration database and the

graphics are generally possible with the appropriate level of
PAGE
privileges.
PAGE
4.7 Applications Of SCADA
We can use SCADA to manage any kind of equipment. Typically,

SCADA systems are used to automate complex industrial processes
where human control is impractical systems where there are
PAGE
more control factors, and more fast-
moving control factors, than human beings can comfortably
PAGE
manage.
PAGE
Around the world, SCADA systems control.
4.7.1 Electric Power Generation, Transmission And
PAGE
Distribution
Electric utilities use SCADA systems to detect current flow and

line voltage, to monitor the operation of circuit breakers, and to
PAGE
take sections of the power grid online or offline.
PAGE
4.7.2 Water And Sewage
State and municipal water utilities use SCADA to monitor and

regulate water flow, reservoir levels, pipe pressure and other
factors.
PAGE
4.7.3 Building, Facilities And Environment
Facility managers use SCADA to control HVAC, refrigeration
PAGE
units, lighting and entry systems.
PAGE
4.7.4 Manufacturing
SCADA systems manage parts inventories for just-in-time

manufacturing, regulate industrial automation and robots, and
monitor process and quality control.
PAGE
4.7.5 Mass Transit
Transit authorities use SCADA to regulate electricity to subways,
PAGE
trams and trolley buses; to automate traffic signals for rail
systems; to track and locate trains and buses; and to control

railroad crossing gates.
PAGE
4.7.6 Traffic Signals
SCADA regulates traffic lights, controls traffic flow and detects
PAGE
out-of-order signals.
SCADA systems provide the sensing capabilities and the

computational power to track everything thats relevant to your
PAGE
operations
PAGE
PAGE
PAGE
FIG:14- SCADA SYSTEMS
4.8. Communications
PAGE
Between Rsview32 and Micrologix :-
PAGE
Communication between Review 32 SCADA and Micrologix

PLC done with Direct Driver. For this First of all communicate
PC with PLC and then go to Rsview32 and make channel, after
this go to node and make a node with Direct Driver.
Between Rsview32 and EXCEL:-
Communication between Rsview 32 SCADA and EXCEL done

with DDE.
PAGE
Between Intouch and Micrologix: -
Communication between Intouch SCADA and Micrologix PLC

done with DDE.
Between Intouch and EXCEL:
PAGE
-Communication between Intouch SCADA and EXCEL also done

with DDE.
PAGE
CONCLUSION
All the different languages have the function of providing the easy
PAGE
programming, program modification and allowing the user the
choice of a most appropriate language for a particular application.

In this way the ease of use and maximum functionality is achieved
without placing any constraints on the possible application of a
PAGE
PLC system. The standardization of the PLC languages and the
programming styles has meant that the common set of languages,

the subject of this report, is supported by all the manufacturers of
the PLC systems. Together with all the other advantages the PLC
systems have over the relay logic systems, they have assumed a
PAGE
dominant position once held by the relay logic controllers in the
PAGE
PAGE
REFRENCES:
[1]
Madhuchhanda
Gupta,Programmable
Automation,penram
PAGE
Ltd.,Third Edition.2005
Mitra
Logic
and
Controllers
International
Samarjit
and
publishing
Sen
Industrial
(India)
Pvt.
[2] Stuart A. Boyer, Scada:Supervisory Control and Data

Acquisition,2nd Edition, April 2006
[3] S.Brian Morriss, Programmable Logic Controllers Prentice
PAGE
Hall Publication, Eighth Edition, July 1999.
[4]Nebojsa
Matric,
Introduction
to
PLC
Controllers,
http://www.aarkstore.com/reports/Home-Automation-Solutions-
PAGE
and-Business-Issues-2009-18434.html
PAGE

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[PLC , SCADA & AUTOMATION REPORT]

A SUMMER TRAINING REPORT

PLC-SCADA AND AUTOMATION

[PLC , SCADA & AUTOMATION REPORT]

Submitted in partial fulfilment of requirements for the award of

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

Saraf Institute of Engineering & Technology

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

An Industrial SCADA and PLC system is used for the development

PLC systems in term of their architecture, their interface to the

[PLC , SCADA & AUTOMATION REPORT]

process hardware, the functionality and the application

development facilities they provide.

[PLC , SCADA & AUTOMATION REPORT]

Some attention is also paid to the industrial standards to which

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

I hereby declare that the work presented in this report entitled

Saraf Institute of Engineering and Technology, affiliated to

[PLC , SCADA & AUTOMATION REPORT]

Rajasthan Technical University, Rajasthan, is an authentic record

of Er. Pawan Punia (HOD, EEE Deptt.)

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

This is to certify that the above

statement made by the candidate is correct to the best of my

[PLC , SCADA & AUTOMATION REPORT]

Er. Pawan Punia (HOD,EEE Deptt.)

[PLC , SCADA & AUTOMATION REPORT]

It gives me immense pleasure to express my deepest sense of

guide Er. Pawan Punia (HOD EEE Deptt.) S.I.E.T, Hanumangarh

[PLC , SCADA & AUTOMATION REPORT]

for their valuable guidance, encouragement and help for

and co-operative behavior are sincerely acknowledged.

[PLC , SCADA & AUTOMATION REPORT]

I would like to express my sincere thank to Mr. Manoj Sharma,

giving me this opportunity to undertake this training.

[PLC , SCADA & AUTOMATION REPORT]

At the end I would like to express my sincere thanks to all my

me directly or indirectly during this project work.

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

What are Controllers.............................23

[PLC , SCADA & AUTOMATION REPORT]

[PLC , SCADA & AUTOMATION REPORT]

2.2.1 PID Controllers..................................23

[PLC , SCADA & AUTOMATION REPORT]

3.1 Introduction to PLC..............................32

[PLC , SCADA & AUTOMATION REPORT]

3.6 Classification of PLC............................38

[PLC , SCADA & AUTOMATION REPORT]