-1-

PROJECT REPORT

Of Training
Undertaken at

Rockwell Automation India Pvt. Ltd.

C-11, Site-IV, Sahibabad Industrial Area
Ghaziabad (U.P.) 201005
on

WATER TANK LEVEL CONTROLLER

Under the Guidance of
RAJEEV GUPTA
MANAGER EXECUTION
Rockwell Automation India Pvt. Ltd.
Submitted by
LALITESH
DECLARATION
I hereby declare that the project entitled LEVEL CONTROLLER FOR LIQUID IN A TANK is
an authentic record of our own work carried out at Rockwell Automation India Pvt. Ltd., as
requirements of project semester for the award of degree of B.Tech./B.E. under the guidance of Mr.
RAJEEV GUPTA, MANAGER EXECUTION, SSB DEPARTMENT, Rockwell Automation India
Pvt. Ltd.
Date: 2nd July, 2015 - 2 -

ACKNOWLEDGEMENT
I take the opportunity to thank those who helped us in successfully making the project. I specially
thank the management for providing us the necessary information for the successful completion of
the project.
I extremely happy to present this project work under the esteemed guidance of Mr. Rajeev Gupta,
Rockwell Automation India Private Limited, Sahibabad-201005. Also, I would like to thank Mr.
Dinesh Singh, Senior Engineer, Rockwell Automation India Pvt. Ltd. for their support and guidance.
I would like to thank all the staff members at Rockwell Automation, who have been very cooperative
and patient with us, and contributed towards making our training a wonderful learning experience.
I like to express sincere thanks and gratitude to our parents who were a constant encouragement for
us. - 3 -

ABSTRACT
Rockwell Automation is the world's largest company dedicated to industrial automation. Throughout
the world, its flagship Allen-Bradley and Rockwell Software product brands are recognized for
innovation and excellence. It manufactures PLC panels for its customers locally and globally. Its
major customers include Ambuja Cement, L&T, SAIL, Reliance Industries Ltd. (RIL), Jindal Steel
Works (JSW), etc. Apart from PLC panels, it develops software under the Rockwell Software brand
to execute its PLC. It also designs SCADA systems for its various customers.
PLC stands for Programmable Logic Controller. It is a solid state device that controls output devices
based on input signals and a user developed application program. It was originally developed to
directly replace relays used for discrete control.
SCADA stands for Supervisory Control and Data Acquisition System. This is a system that enables a
controller setup at one location to monitor and control various field devices at remote locations.
Major learning points:
Analyzing the Piping and Instrumentation (P&I) diagrams provided by the customer.
Using the input/output (I/O) list provided by the customer, develop the SCADA screens of
FactoryTalkView Studio software in Site (Local) or Machine Edition.
Downloading the RSLogix program on a specific slot of controller chassis.
Setting up the communication to import and assign various tags (memory elements) to inputs and
outputs.
Generating alarms for various components such as motors, pumps, valves, etc.
Building client interface in FactoryTalkView Client software and running the SCADA screen to
check for errors and correcting them.
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INDEX
Page No.
1. INTRODUCTION............6
1.1 Company Overview...6
1.1.1 Company History..7
1.1.2 Products....8
1.1.3 General Structure of the Company...9
1.2 Project Overview....9
1.2.1 Project Objectives...10
2. PLC AND LADDER LOGIC.11
2.1 Basics of PLC and Ladder Logic.11
2.1.1 How did the PLC get started?.....................................................11
2.1.2 What is a PLC?...........................................................................11
2.1.3 Steps involved in creating and downloading logic in PLC12
2.1.4 Ladder Logic..13
2.2 Using RSLogix 5000.13
2.2.1 Ladder logic for the project...14
2.3 Basics of SCADA Systems16
3 DESIGNING SCADA SYSTEMS....18
3.1 Introduction...18
3.1.1 FactoryTalk View Studio....19

3.1.2 Piping and Instrumentation (P&ID) Diagram.20

3.1.3 Input/output (I/O) List.22
3.2 Building a Graphic Display..22
3.2.1 Creating and Using Global Objects23
3.3 Configuring Comm. using RSLinx Enterprise Device Server......24
3.3.1 Adding an RSLinx Enterprise Driver..24
3.4 Controller Tags..25
3.4.1 Setting up Data Server Tags.....26
3.4.2 Setting up HMI Tags....27
3.5 Animating Graphic Objects.27
3.6 Generating Alarms....28
-5-

3.7 Launching FactoryTalk View SE Client.......30

4 PROJECT SIMULATION..32
4.1 Using RSLogix Emulate 5000.32
5 CONCLUSION.33
6 REFERENCES....34
-6-

LIST OF ABBREVIATIONS
AB: Allen-Bradley
ACL: Ambuja Cement Ltd.
DA: Data Access
DMRC: Delhi Metro Rail Corporation
GA: General Arrangement
GM: General Motors
HMI: Human Machine Interface
ICS: Industrial Control System
I/O: Input/output
IP: Internet Protocol
JSW: Jindal Steel Works
LIU: Light Interface Unit
ME: Machine Edition
NO/NC: Normally Open/ Normally Closed
PAC: Programmable Automation Controller
P&ID: Piping & Instrumentation Diagram
PLC: Programmable Logic Controller
PSCA: Power Supply Common Adapter
PSU: Power Supply Unit
RAM: Random Access Memory
RS: Rockwell Software
RTD: Resistance Temperature Detector
RTU: Remote Terminal Unit
SCADA: Supervisory Control and Data Acquisition
SE: Site (Local) Edition
SSB: System Solutions Business 6

1 INTRODUCTION
1.1 Company Overview
Rockwell Automation helps manufacturers succeed and grow with industrial automation control
and information solutions designed to their customers competitive advantage. From standalone
industrial components to enterprise wide integrated systems, solutions provided by Rockwell have
proved themselves across a wide range of industries and in some of the most demanding
manufacturing environments.
Faster time to market- through the speed, responsiveness and flexibility of automated
manufacturing.
Lower total cost of ownership through scalable, modular, energy efficient and open automation
control and information systems.
Better asset management/optimization- through diagnostics, condition-based monitoring,
failure analysis and storage management.
Broader manufacturing business risk management- through process variability analysis,
regulatory compliance and safety solutions.
Around the world Rockwell Automation is committed to putting its customers need first. The global
capabilities of Rockwell extend across 80 countries and include a Partner Network of more than 5600
regional and global specialists in distribution, system integration and product referencing.
To put it simply Rockwell Automation is there with the right solution when and where their
customers need them and they are well positioned to provide leading edge solutions for years to
come. Backed by strong financial based Rockwell Automation continues to acquire expertise and
invest in the aggressive research and development that fuels innovation.
Figure 1.1: The logo of Rockwell Automation 7

Allen-Bradley is the brand-name of a line of Factory Automation Equipment manufactured by

Rockwell Automation (NYSE ROK). The company, with revenues of approximately US$4.5 billion
in 2006, manufactures programmable automation controllers (PAC, PLC), human-machine
interfaces, sensors, safety components and systems, software, drives and drive systems, contactors,
motor control centers, and systems made of these and similar products. Rockwell Automation also
provides asset management services including repair and consulting. Rockwell Automation's
headquarters is based in Milwaukee, WI.
The Allen-Bradley Clock Tower is a Milwaukee landmark featuring the largest four-sided clock in
the western hemisphere.
Figure 1.1: Logo used by Allen-Bradley prior to its acquisition by Rockwell Automation.

Allen-Bradley is the same name associated with low temperature sensors, since a now obsolete line
of carbon-composite resistors manufactured by Allen-Bradley shows approximately inversely
proportional temperature dependence at low temperatures. This undesirable characteristic for
commercial resistors (since an ideal resistor should have no temperature dependence) is suited for
cryogenic measurement, which paradoxically has partly helped establish a name for Allen-Bradley
among the lay electronic enthusiast. Allen-Bradley resistors are commercially available at a
premium, often supplied with calibration data.
1.1.1 Company History
Rockwell Automation was initially founded in 1903 as the Compression Rheostat Company by
Lynde Bradley and Dr. Stanton Allen with an initial investment of $1,000. In 1910, the company was
renamed the Allen-Bradley Company. In 1952 they opened a subsidiary in Galt, Ontario, Canada that
now employs over 1000 people. In 1985 a new company record was set as they 8

ended the fiscal year with 1 billion dollars in sales. On February 20, 1985 Rockwell International
(now Rockwell Automation) purchased Allen-Bradley for $1.651 billion, which is the largest
acquisition in Wisconsin's history.
Rockwell Automation spun off from in 2001. From there, Rockwell Automation went through a
series of acquisitions, particularly Propack Data (now Rockwell Automation Solutions GmbH) in
2002, DataSweep in 2005, GEPA in 2006, ICS Triplex, ProsCon and Pavilion Technologies in 2007,
and Incuity in 2008 and Lektronix Ltd in 2011. On January 31, 2007, Rockwell Automation sold off
their PowerSystems Division which consists of Dodge mechanical and Reliance Electric motors with
headquarters in Greenville, South Carolina to Baldor Electric Company.
1.1.2 Products
Some examples of Rockwell Automation's industrial automation offerings are:
Programmable Automation Controllers: CompactLogix, ControlLogix, FlexLogix, SoftLogix5800

and DriveLogix
Programmable Logic Controllers: PICO, Micro 800, MicroLogix, SLC500, PLC5 and Datasite

RTU
I/O: FlexIO, CompactIO, PointIO, etc.
HMI: PanelView Standard, PanelView enhanced, PanelView Plus, Industrial Computers &

Monitors, etc.
Industrial Safety Products: GuardLogix, SafetyIO, XM Vibration Monitors, etc.
Variable frequency drives-PowerFlex Drives, Drive Systems.
Software:
o Rockwell Software Brand: RSNetWorx, RSLinx, PMX, FactoryTalk etc.
Motor Controllers: MCCs (Allen-Bradley's CENTERLINE MCC with IntelliCENTER

Technology), industrial control (contactors, overloads, circuit breakers etc.)

Condition Monitoring/Vibrational Analysis: Entek

Sensors, Photoelectric, Capacitive, Inductive, Ultrasonic: Rockwell Automation/Allen-Bradley

Sensors. 9

1.1.3 General Structure of the Company

There are generally three divisions in the Sahibabad facility of Rockwell Automation, they are as
follows:
SSB (Systems Solution Business) Its main function is the manufacturing of the panel as per
design given by the customer which includes software design and hardware design, fitting and
assembling, electrical wiring and cabinet design.
Sales Department Its function is the proposal preparation according to the tender from the
customer and negotiates the prices with customers for winning orders.
Purchase Department Its function is to buy the materials required for the manufacturing of
panels.

1.2 Project Overview

PLC stands for Programmable Logic Controller. It is a solid state device that controls output devices
based on input signals and a user developed program. It was originally developed to directly replace
relays used for discrete control.
Testing and Troubleshooting PLC panels require following steps to be followed:
Physical Inspection of panels using General Arrangement (GA) diagram, System Configuration
and Power Distribution diagrams.
Scheduling of network using RSLinx and RSNetworx softwares.
Framing the Input/Output (I/O) tree for the network that includes all the modules such as
Controllogix, EtherNet, Digital Input, Digital Output, etc.
Downloading the program on the controller.
Forcing the inputs high and receiving the output on the system to check for wiring errors.
SCADA stands for Supervisory Control and Data Acquisition System. This is a system that enables a
controller setup at one location to monitor and control various field devices at remote locations.
Designing SCADA system requires following steps to be followed:
Analyzing the Piping and Instrumentation (P&I) diagrams provided by the customer.
10

 Using the input/output (I/O) list provided by the customer, develop the SCADA screens of
FactoryTalkView Studio software in Site (Local) or Machine Edition.
Downloading the RSLogix program on a specific slot of controller chassis.
Setting up the communication to import and assign various tags (memory elements) to inputs and
outputs.
Generating alarms for various components such as motors, pumps, valves, etc.
Building client interface in FactoryTalkView Client software and running the SCADA screen to
check for errors and correcting them.
1.2.1 Project Objectives
To develop the ladder logic using RSLogix 5000 (PLC programming software) and Control Room
display client using FactoryTalk View Studio (SCADA software) to show the status of the system.
The system would be used to control the level of liquid in a tank using two pumps (one for inlet and
one for outlet) and valves.
The system should have the following functionalities:
The system can either be in the Manual mode or the Automatic mode.
In the Manual mode, the user can start or stop the pumps and open or close the valves based on
his requirement.
In the Automatic mode, the level of liquid in the tank would be controlled by certain predefined
conditions. If the liquid level is below 20%, the inlet motor will start. If the liquid level reaches 60%
while rising, the outlet motor will start. If the liquid level reaches 80% while rising, the inlet pump
will stop. If the liquid level reaches 10% while falling, the outlet pump will stop.
11

Networks (Ethernet, RS232, ControlNet, etc.)

2 PLC AND LADDER LOGIC

2.1 Basics of PLC and Ladder Logic

2.1.1 How did the PLC get started?

A little history In the 1960s, General Motors (Hydramatic Division) approached a number of its
suppliers to help with a problem.Relay walls covered the plant floor.Troubleshooting took
weeks.Every change (model year) was major destruction and re-wiring.The expense of doing this
was very high and took several weeks/months to complete.
GM needed the flexibility of solid state; a controller that could be programmed and maintained by
plant engineers; and was rugged enough to withstand the factory environment and provided easy
troubleshooting.
2.1.2 What is PLC?
A PLC is a solid state device that controls output devices based on input signals and a user developed
program. It was originally developed to directly replace relays used for discrete control.
Figure 2.5: PLC at a glance 12

2.1.3 Steps Involved in Creating and Downloading the Logic in PLC

Assign IP address to PC and driver (1756-EN2T) using BOOTP software.
Configure driver using RSlinx software.
Create a new project in RSlogix 5000 software.
Write the LADDER logic in RSlogix software.
Download the program to controller.
Driver Backplane
Controller 1756-ENBT Module
Figure 2.6: Downloading logic in PLC 13

2.1.4 Ladder Logic

Ladder logic is the main programming method used for PLCs. As mentioned above, ladder logic has
been developed to mimic relay logic. The decision to use the relay logic diagrams was a strategic
one. By selecting ladder logic as the main programming method, the amount of retraining needed for
engineers and trades people was greatly reduced.
Modern control systems still include relays, but these are rarely used for logic. A relay is a simple
device that uses a magnetic field to control a switch.
Figure 2.7: Example of Ladder Logic

2.2 Using RSLogix 5000

With RSLogix 5000 Enterprise Series software is a programming software for sequential, process,
drive, and motion control programming. The RSLogix 5000 Enterprise Series environment offers an
easy-to-use interface, symbolic programming with structures and arrays, and an instruction set that
serves many types of applications. 14

Figure 2.8: RSLogix 5000

2.2.1 Ladder Logic for the project
15 16

First, the mode is set to either Automatic or Manual. Then the logic for opening the valve is
implemented after checking for the required level conditions or if the Valve Push Button is pressed.
Once the valve has opened, the Valve FeedBack is used to latch the Valve opening. Once the valve
has opened, the logic for running the motor to start the pump has been implemented. The pump starts
only while the valve is open, the motor does not trip, and the motor alarm does not get activated. The
motor alarm is activated after five seconds of giving the signal if the motor fails to start or fails to
stop.

2.3 Basics of SCADA

SCADA (Supervisory Control And Data Acquisition) generally refers to industrial control systems
(ICS): computer systems that monitor and control industrial, infrastructure, or facility-based
processes, as described below:
Industrial processes include those of manufacturing, production, power generation, fabrication
and refining, and may run in continuous, batch, repetitive, or discrete modes.
Infrastructure processes may be public or private, and include water treatment and distribution,
wastewater collection and treatment, oil and gas pipelines, electrical power
17

transmission and distribution, wind farms, civil defence systems, and large communication systems.
Facility processes occur both in public facilities and private ones, including buildings, airports,

ships, and space stations. They monitor and control HVAC, access, and energy consumption.
A SCADA system usually consists of the following subsystems:
A human machine interface or HMI is the apparatus or device which presents process data to a
human operator, and through this, the human operator monitors and controls the process.
A supervisory (computer) system, gathering (acquiring) data on the process and sending

commands (control) to the process.

Remote terminal units (RTUs) connecting to sensors in the process, converting sensor signals to

system data and sending digital data to the supervisory system.

Programmable Logic Controllers (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.
Various process and analytical instrumentation

The term SCADA usually refers to centralized systems which monitor and control entire sites, or
complexes of systems spread out over large areas (anything from an industrial plant to a nation).
Most control actions are performed automatically by RTUs or by PLCs. Host control functions are
usually restricted to basic overriding or supervisory level intervention. For example, a PLC may
control the flow of cooling water through part of an industrial process, but the SCADA system may
allow operators to change the set points for the flow, and enable alarm conditions, such as loss of
flow and high temperature, to be displayed and recorded. The feedback control loop passes through
the RTU or PLC, while the SCADA system monitors the overall performance of the loop. 18

3 DESIGNING SCADA SYSTEMS

3.1 Introduction
At Rockwell Automation, SCADA systems are designed in FactoryTalk View Studio software. This
software allows the user to develop SCADA systems in Site (Local) Edition, Machine Edition, Site
(Network) Edition or Network Distributed Edition.
Figure 3.1: FactoryTalk View Studio

FactoryTalk View SE software is a part of the FactoryTalk View Enterprise Series family of products
which provide a common HMI solution for machine-level and supervisory-level applications.
Local (Stand-alone) Applications: FactoryTalk View SE software components are installed on one
computer. If needed, additional data servers can send data to the computer hosting the stand-alone
application.
19

Figure 3.2: Local (Stand-alone) Application

Network (Distributed) Applications: FactoryTalk View SE software components are spread out
among multiple servers and client computers.
Figure 3.3: Network (Distributed) Applications

3.1.1 Factory TalkView Studio

The FactoryTalk View Studio development environment is used to create, open, build, and modify
FactoryTalk View SE applications.
After creating a new application or opening an existing application, the main software screen is
displayed: 20

Figure 3.4: Display after creating new application or opening existing one

3.1.2 Piping and Instrumentation (P&ID) Diagram

The P&ID shows the flows in a plant (in the chemical or process industry) and the corresponding
sensors or actors. At the same time, the P&ID gives a name ("tag") to each sensor and actor, along
with additional parameters. This tag identifies a "point" not only on the screens and controllers, but
also on the objects in the field.
The P&ID mixes pneumatic / hydraulic elements, electrical elements and instruments on the same
diagram. It uses a set of symbols defined in the ISA S5.1 standard. 21

Figure 3.5: Various Symbols used in P&IDs

Table 3.1: General Instrument or Function Symbols Figure 3.5: Various Symbols used in P&IDs 22

Figure 3.6: Example of P&ID

3.1.3 Input/output (I/O) List

I/O list provides the details about the digital or analog inputs and outputs to be shown on the SCADA
screen. It only consists of electronically controlled equipments such as valves, pumps, motors, etc.
and does not include the manually controlled equipments.
Figure 3.7: Example of I/O list

3.2 Building a Graphic Display

After opening a new application or an existing one, a new graphic display can be built by right
clicking on Displays option in the Explorer Window on the left side. 23

Figure 3.8: Creating a new display

After clicking on New, a new graphic display opens up. Different objects can be placed or
designed on this display to create a static SCADA screen.
Figure 3.9: Static SCADA Screen

3.2.1 Creating and Using Global Objects

Global objects can be created or added from other displays libraries. When an object is added to a
Global Objects graphic display it becomes a base object that can be referenced from a standard 24

graphic display. A global object can be copied onto any number of displays, or multiple times onto a
single display.
Figure 3.10: Creating Global Objects

At run time, when a standard display that contains reference objects is run, the global object display
that contains the corresponding base objects is loaded in the background.
When you copy or drag a global object onto a standard graphic display, the resulting reference object
has several new properties called Link properties. The Link properties are initially given default
values that you can change by setting the global object defaults:
3.3 Configuring communications using an RSLinx Enterprise Device Server
RSLinx Enterprise is a device server that links networks and devices to Microsoft Windows 2000-,
XP-, and CE-based applications. It provides communication services between your applications and
devices on the plant floor so that on your Windows computer, you can see your controller (PLC)
data.
3.3.1 Adding an RSLinx Enterprise Driver
In order to communicate to your controller, you must first add an RSLinx Enterprise Device Server:
Figure 3.11: Adding RSLinx Enterprise Device Server

After your RSLinx Enterprise Server has been 25

created, you can configure your communication setup:

Figure 3.12: Configuring Communication Setup

In the Communication Setup Editor, you can:

Add drivers
Add devices
Create shortcuts
Figure 3.13: Communication Setup Editor Window

3.4 Controller Tags

26

A tag is a logical name for a variable in a device or in local memory (RAM). For example, a tag can
represent a process variable in a programmable controller. Tags are, basically, of two types:
Data Server Tags: FactoryTalk View conforms to the OPC DA (Data Access) 2.05a specification
for information exchange among automation or control applications, field systems or devices, and
business or office applications. In FactoryTalk View, data servers such as RSLinx Enterprise, RSLinx
Classic, and KEPServer Enterprise provide access to OPC-DA-compliant tags. In the FactoryTalk
View documentation, the tags used through a data server are called data server tags.
HMI Tags: In addition to direct referencing tags from data servers, FactoryTalk View allows you
to create tags with additional properties such as minimum and maximum values, scale, and offset.
These tags can reference values at an external data source, or store values in the run-time computers
memory. Tags created in FactoryTalk View are called HMI tags.
Figure 3.14: Creating HMI Tags

3.4.1 Setting up data server tags

To use data server tags, such as those found in Logix5000 and other OPC-compliant devices, you can
refer directly to the tags location wherever the tag data is needed.
These are the basic tasks involved in setting up data server tags for an application:
1. Create the tag in the OPC server or processor, or use an existing tag in the processor.
2. In FactoryTalk View Studio, in the Explorer window, add a data server to the application, if it
doesnt already have one.
27

3. Connect application components to the data server tags, wherever the application needs to use the
tag values.
3.4.2 Setting up HMI Tags
To use tags stored in an HMI servers tag database, connect the tags to addresses in network devices,
and then refer to the HMI tags wherever the tag data is needed.
These are the basic tasks involved in setting up HMI tags for an application:
1. In FactoryTalk View Studio, in the Explorer window, add an HMI server to the application, if it
doesnt already have one. Each HMI server contains one tag database.
2. In the Tags editor, create HMI device tags by mapping tag names to data server or DDE addresses,
or create HMI memory tags.
3. Connect application components to the HMI tags, wherever the application needs to use the tag
values.
3.5 Animating Graphic Objects
After creating a graphic display or a static SCADA screen, graphic objects can be animated to
develop a Dynamic SCADA Screen.
Various types of animations available in FactoryTalk View are:
Visibility
Color
Fill
Horizontal and Vertical Position
Width and Height
Rotation
Touch
Horizontal and Vertical Slider
28

Figure 3.15: Animating Graphic Objects

Figure 3.16: Example of Fill Animation

3.6 Generating Alarms

An alarm occurs when something goes wrong or is about to go wrong. Alarms can signal that a
device or process has ceased operating within acceptable, predefined limits, and can indicate
breakdown, wear, or process malfunctions. Alarms are also used to indicate the approach of a
dangerous condition.
To create alarms in FactoryTalk View, following steps have to be followed:
1. In the Explorer Window on the left, create a new alarm server by right clicking on the project
name and selecting Add New Server and then Tag Alarm and Event Server.
29

Figure 3.17: Adding a new alarm server

2. Select Alarm and Event Setup from Alarm Server and create an alarm for any parameter.
Figure 3.18: Creating Alarms

3. These alarms can be exported as an Excel file, where more alarms can be created.
30

Figure 3.19: Exporting Alarms

Figure 3.20: Creating more Alarms in Excel

4. After creating all the alarms, this Excel file can be imported in FactoryTalk View to generate all
the alarms.
3.7 Launching FactoryTalk View SE Client
FactoryTalk View SE Client represents the final module that is visible on the operators system. To
launch SE client:
1. Click on the Launch SE Client option in the Standard Toolbar.
31

2. Develop a new configuration file; specify the type of SE application, its name, location and the
initial display and parameters.
Figure 3.21: Launching SE Client

After generating all that is mentioned above, SCADA application is ready to be installed at site. 32

4 PROJECT SIMULATION
4.1 Using RSLogix Emulate 5000
RSLogix Emulate 5000 is a software product that emulates the behavior of ControlLogix controllers.
The emulator allows experimentation with and debugging of Logix5000 programs in a safe,
controlled environment without investing in physical controllers and I/O modules. Additionally,
RSLogix Emulate 5000 allows the testing of HMI applications without using a real controller.
Figure 4.1: RSLogix Emulate 5000 Chassis Monitor 33

5 CONCLUSION
5.1 Major learning from the Project
Rockwell Automation is the worlds largest automation company. It manufactures PLC panels for its
various customers such as Reliance Industries Ltd, SAIL, Jindal Steel Works (JSW), Ambuja Cement
Ltd., etc.
The projects covered in the training from June 2015 to July 2015 are:
1) BUTADIENE EXTRACTION UNIT,PANIPAT REFINERY PROJECT(BY IOCL)
Designing of SCADA systems require following steps to be followed:
Analyzing the Piping and Instrumentation (P&I) diagrams provided by the customer.
Using the input/output (I/O) list provided by the customer, develop the SCADA screens of
FactoryTalkView Studio software in Site (Local) or Machine Edition.
Downloading the RSLogix program on controller.
Setting up the communication to import and assign various tags (memory elements) to inputs and
outputs.
Generating alarms for various components such as motors, pumps, valves, etc.
Building client interface in FactoryTalkView Client software and running the SCADA screen to
check for errors and correcting them.
2) LEVEL CONTROLLER FOR A LIQUID IN A TANK
Develop the logic for the system in RSLogix 5000
Develop the SCADA screens in FactoryTalk View
Simulate the project using RSLogix Emulate 5000
34

REFERENCES
[1] Rockwell Automation India Pvt. Ltd. Available at www.rockwellautomation.com. Accessed from
January 2015 to May 2015.
[2] Rockwell Software Support. Available at
http://www.rockwellautomation.com/rockwellsoftware/support/overview.page?. Accessed in January
2015.
[3] Rockwell Software Library. Available at
http://www.rockwellautomation.com/sites/rockwellsoftware/support/libraries.page. Accessed in
March 2015.
[4] Rockwell Literature. Available at
http://literature.rockwellautomation.com/idc/groups/public/documents/webassets/browse_category.hc
st. Accessed from January 2015 to May 2015.
[5] FactoryTalk View SE User Guide. Available at Help in FactoryTalk View Studio Site Edition
(Local). Accessed in January 2015.
[6] FactoryTalk View ME User Guide. Available at Help in FactoryTalk View Studio Machine
Edition. Accessed in January 2015.
Apart from these, the training material provided by the staff of Rockwell Automation has been
extensively used in the making of this report.