INDUSTRIAL TRAINING REPORT

Carried out at

RVM CONTROLS, SONIPAT, HARYANA

Submitted for the partial fulfillment for the award of the degree of:-
BACHELOR OF TECHNOLOGY
(ELECTRICAL & ELECTRONICS ENGINEERING)

Submitted by
VARUN KUMAR PANDEY (10520210008)
SRM UNIVERSITY, DELHI-NCR, SONIPAT, HARYANA

Under the guidance of

Dr. RB DUBEY (EEE DEPARTMENT)

DEPT.OF ELECTRICAL & ELECTRONICS ENGINEERING,

SRM UNIVERSITY, DELHI-NCR, SONIPAT, HARYANA.

1
 Goal of Training

The goal of undergoing this industrial training (internship) was to gain core
knowledge of AUTOMATION IN ELECTRICAL FIELD in India. During this
training, I was taught about various techniques of programming the different logic
controllers, HMIs, SCADA systems etc. And I was also taught about the
automation industry in India.

2
 ACKNOWLEDGEMENT

Materials in this report have been drawn from a wide variety of sources including
weekly journals , books, magazines and internet. Some data is recorded directly
from RVM Controls officials and I hope that I have made no omissions.
An engineer with only theorotical knowledge is not a complete engineer.
Practical knowledge is very important to develop and apply engineering skills. It
gives me a great pleasure to have an opportunity to acknowledge and to express
gratitude to those who were associated with me during my training at RVM
Controls, Sonipat, Haryana.
Special thanks to college for providing me with an opportunity to undergo
training under his able guidance and offering me a very deep knowledge of
practical aspects of industrial work culture. I express my sincere thanks and
gratitude to RVM Controls authorities for allowing me to undergo the training in
this prestigious organization. I will always remain in debuted to them for their
constant interest and excellent guidance in my training work, moreover for
providing me with an opportunity to work and gain experience.
I am deeply indebted to Mr. JAI SING JAKHAR ( SUPERINTENDENT
ENGINEER [RVM Controls] ) and MR. VIKAS ( JUNIOR ENGINEER [RVM
Controls] ) without whose support and encouragement this traning couldn’t have
been accomplished

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INDUSTRIAL TRAINING CERTIFCATE

4
 ABOUT
RVM Controls Pvt. Ltd.
Sonipat, Haryana

R V M Controls Private Limited is an unlisted private company incorporated on

03 February, 2009. It is classified as a private limited company and is located in
New Delhi, Delhi. It's authorized share capital is INR 5.00 lac and the total paid -
up capital is INR 2.00 lac.
This firm provides Electrical & Mechanical maintenance service to offset
printing machines.
They also deal in sales & purchase of those machines. Along with all that they
are leading competitors in
Automation Industry as well.

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Table of Content

P.NO

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.48
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 General Abbreviation
PLC: Programmable logic controllers.
SCADA: Supervisory control and data acquisition.
I/P: Input O/P: Output.
T-On: On timer.
T-Off: Off timer.
M: Memory Bits.
Q: Output in program.
MW: Memory words.
NO: Normally open.
NC: Normally closed.
DCS: Distributed Control System.
HMI: Human machine interference.
VFD: Variable Frequency Drive.
MD: Memory Double Word.
MB: Memory Byte
XIC: Examine If Closed
XIO: Examine If Open

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 AUTOMATION
Introduction
Automation is the use of control system such as computers to control industrial
machinery & process, reducing for need for human intervention. In the scope of
industrialization,
Automation is a step beyond mechanization. whereas mechanization provided
human operators with machinery assist them with physical requirement of work,
automation greatly reduces the need for human sensory and mental requirements
as well. Process and system can also be automated.

In other words
Automation is a delegation of human control function to technical equipment for
increasing productivity, to better quality, to reduce cost & increase in safety
working condition, to reduce manpower.
Example of automation
Automatic machine tools to process parts- CNC m/c
Industrial robots
Automatic material handling
Feedback control system

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 EXAMPLE OF AUTOMATION

Automatic Material Handling

Conveyors.

Industrial Robots

feedback control systems

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 TYPES OF AUTOMATION

Fixed automaton
Programmable automation
Flexible automation
Fixed automation
Fixed automation refers to the use of custom-engineered (special purpose)
equipment to automated a fixed sequence of processing or assembly operations.
This is also called hard automation.
The primary drawbacks are the large initial investment in requirement and the
relative flexibility.
Programmable automation
In programmable automation, the equipment is designed to accommodated a
specific class of product changes and the processing or assembly operation can be
changed by modifying the control program.
Flexible automation
In flexible automation, the equipment is designed to manufacture a variety of
products or parts and very little time is spend on changing from one product to
another . A flexible manufacture various combination of products according to any
specified schedule.
INDUSTRIAL AUTOMATION
PLANT

Field
instrument

Intelligent
controller

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 Field instrument
This type of instrument mainly used to get the feedback any type of process carried
our so they mainly plant used
Sensors, Transducer, Transmitter

Proximity Sensor.
Intelligent controller
This device are basically micro control based or micro controller device mainly
intelligent controller are:
Programmable logic controller (PLC)
PID Controller
Distributed controller system (DCS)
Computer Numerical controller (CNC

PLC

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 PID

CNC MACHINE
Monitoring and controller
This type of device to control whole plant just in a setting in control room, so
mainly control device are
Supervisory Control & Data Acquisition (SCADA)

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Human Machine interface (HMI)

600 Series touch screen HMI.

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 PROGRAMMABLE LOGIC CONROLLER
Introduction
A PLC is a solid device designed to perform the function previously accomplished
by components such as electromechanical relay, drums switch, mechanical timers
/counter etc. for the control and operation of manufacturing process equipment and
machinery. Even thought the electromechanical relay (control relay, pneumatic
timer relay, etc ) have served well for many generations, often under adverse
conditions, the ever increasing sophistication and complexity of modern
processing equipment requires faster acting, more reliable functions that
electromechanical relays or timing devices can’t offer.
What is relay?
A relay is an electromechanical switch, operated by passing current through a coil
wire wound around a steel core, which act as an electromagnet pulling the switch
contact down or break a circuit

HISTORY OF PLC
The first programmable logic controller were designed and developed by Modicon
as a relay replacer for GM and landis.

This controller eliminated the need for rewiring and adding additional for each new
configuration of logics.
The new system drastically increased the functionality of the control while
reducing the cabinet space that housed the logic.
The first PLC, model 084, was invented by Dick Morley in 1969.
The first commercial successful PLC, the 184, was introduced in 1973 and was
designed Michael Greenberg.

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 ADVANTAGES
PLC not only capable of performing the same tasks as hard-wired control, but are
also capable of many more flexible application. In addition, the PLC program and
electronic communication lines replace much of the interconnecting wires require
hardwire control. Therefore, hard wiring, thought still required to connect field
device, is less intensive. This also makes correcting errors and modified the
application easier.
Some of the additional advantages of PLCs are as follow
Smaller physical size than hard-wire solutions
Easier and faster and to make changes.
PLCs have integrated diagnostics and override functions
Diagnostics are centrally available
Application can be immediately documented
Application can be duplicated faster and less expansively
Speed in operation
Security
Online/ offline modifications

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Photograph showing several input and output modules of a single Allen-Bradley
PLC.
INSIDE PLC
The Central processing Unit (CPU), contains and internal program that tells the
PLCs how to perform the following functions:

Execute the control instructions contained in the user’s Programs. This program is
store in “nonvolatile” memory, Meaning that the program will not be lost if power
is removed.
Communicate with other device, which can include I/O
Device, programming device, networks and even other PLCs
Performs housekeeping activities such as communication, internal diagnostic, etc.

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THE CPU
The microprocessor or processor module is the brain of PLC system. It consists of
the microprocessors, memory integrate circuits, and circuits necessary to store and
retrieve information from memory. It also includes communication ports to the
other peripherals, other PLCs or programming terminals. Today’s processors vary
widely in their capabilities to control the real world devices. Some control as few
as 6 inputs and

outputs (I/O) and other 40,000 or more. One processor can be control more than
one process or manufacturing line. Processors are often linked together in order to
provide continuity throughout the process.
RAM
RAM or Random Access Memory is a volatile memory that would lose its
information if power were removed. This is why some processors units incorporate
a battery back-up.
This type of RAM normally used CMOS or Complementary Metal Oxide
Semiconductor.
CMOS RAM is used for storage of the user’s program (ladder logic diagrams) and
storage memory.
ROM
ROM or Read only memory is a non volatile memory. This means you don’t need
external power source to keep information. In this type of memory, information
can be read, but not changed. For these reason the manufacture sometimes calls
this firmware. It is placed their for the internal use and operation of processors
units.

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EEPROM
EEPROM or Electrically Erasable programmable Read Only Memory is usually
an add-on memory module that is used to back of the main program in COSMOS
RAM of the processors. Can be programmed to load the EEPROM’s program to
RAM is lost or corrected.

INPUT MODULE
There are many types of input module to choose form. These type of module used
is dependent upon what real world input to the PLCs is desired. Some example
input are limit switches, electric eyes, and pushbuttons. DC input, such as
thumbwheels switches, can be used to enter integer values to the manipulated by
the PLC, DC input cards are used for this application. Since most industrial power
systems are inherently noisy, electrical isolation is provided between the input and
the processor. Electromechanical interference (EMI) and radio frequency
interference (RF) can be cause severe problems in most solid state control systems.
The component used most often to provide electrical isolation within I/O cards is
called an optical isolator. The wiring of an input is not complex. The object is to
get a voltage at a particular point on the card. Typically there are 8 to 32 input
points on any one input module. Each point will be assigned a unique address by
the processor. Analog input modules are special cards that use analog to digital
conversion (A to D) to sense variables such as temperature, speed, pressure and
position. The external device normally is connect to a controller (transducer)
producing an electrical signal the analog input card can interpret. This signal is
usually 4 to 20 Ma or 0 to 10 volts.

OUTPUT MODULE

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Output modules can be used for ac or dc devices such as solenoids, relay,
contractor, pilot lamps, and LED readouts. Output card usually have from 6 to 32
outputs on a signal module. The output device within the cards provides the
connection from the user power supply to the load. Usually silicon controlled
rectifier (SCR), triac, or dry contact relay are use for this purpose. Individual
output are rated most often at 2 to 3 amperes. Output cards, like input cards have
electrical isolation between the load being connected and the PLC. Analog output
cards are a special type of output modules that use digital to analog conversion (D
to A). The analog output module can be take a value store in a 12 bit file and
convert it to an analog signal. Normally this signal is 0-10 volts dc or 4 to 20 Ma.
This analog signal is often used in equipment such as motor operated valves and
pneumatic position control device.

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 SENSORS
A sensor is a device that converts a physical condition into an electrical signal for
use by the
PLC. Sensors are connected are input of a PLC. A pushbutton is one example of
sensors that is connected to the PLC input. An electrical signal is sent from the
pushbutton to the PLC indicating the condition (open/closed) of the pushbutton
contacts.

ACTUATOR
Actuators convert an electrical signal from the PLCs into a physical condition.
Actuators are connected to the PLC output. A motor starter is one example of
actuator that is connected to the PLC output. Depending on the PLC signal the
motor starter will either start or stop motor.

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 NUMBER SYSTEM
Since PLCs is computer it stores information in the form of on or off conditions (1
to 0), refers to as binary digits (bits). Sometimes binary digits are used individually
and sometimes they are used to represent numerical valves.
DECIMAL SYSTEM
Various number system are used by PLCs. All number systems have the same
three characteristic:
Digits
Base
Weight.

The decimal system, which is commonly used in everyday life, has the following
characteristic:
Ten digits 0,1,2,3,4,5,6,7,8,9
Base 10
Weights 1, 10, 100, 1000……

BINARY SYSTEM
The binary system is used by programmable controllers. The binary system has the
following characteristic:
Two digits 0,1
Base 2
Weights power of base 2 (1, 2, 4, 8, 1, 6……)
In the binary system 1s 0s are arranged into columns. Each column is weights. The
first column has a binary weight of 2°.
This is equivalent to decimal 1. This is referred to as the least significant bit. The
binary weight is double with each succeeding column. The next column, for
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example, has a weight of 2^1which is equivalent to decimal 2. The decimal value
is double in each successive column. The number in the far left hand column is
referred to as the most significant bit. In this example, the most significant bit has
a binary weight of 2^7. This is equivalent to decimal to 128.

CONVERTING BINARY TO DECIMAL

The following steps can be used to interpret a decimal number from a binary value.
Search from least to most significant bit for 1s .
Write done the decimal representation of each column containing a 1.
Add the columns values.
In the following example, the fourth and fifth columns from the right containing a
1.The decimal values of the fourth column from the right is 8, and the decimal
value of the fifth column from the right is 16. The decimal equivalent of this binary
number is 24. The sum of all the weighted columns that contains a 1is the decimal
number that the PLC has stored

BITS, BYTES, AND WORDS

Each binary piece of data is a bit. Eight bits make of one byte.
Two bytes, or 16 bits, make of one word.

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 21
LOGIC 1, LOGIC 0
Programmable controllers can only understand a single that that is on or off
(present or not present).the binary system is a system in which there are only two
numbers, 1 and 0.
Binary 1 indicates that a signal is present, or the switch is on.
Binary 0 indicates that a signal is present, or the switch is off.

BCD (Binary-coded decimal)

Binary-coded decimal (BCD) are the decimal number where the each digit is
represented by a four-bit binary number. BCD is commonly used with input and
output devices. Thumbwheel stitch is one example of an input device that uses
BCD. The binary number are broken into group of four bits, each group
representing decimal equivalent. A four-digit thumbwheel switch, like the one
show here, would control 16 (4*4) PLC inputs.

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HEXADECIMAL
Hexadecimal is another system used in PLCs. The hexadecimal has the following
characteristic:
16 digits 0,1,2 ,3,4,5,6,7,8,9,A,B,C,D,E,F
Base 16, weights power of base 16(16, 256, 4096…..)
The ten digits of the decimal system are used for the first ten digits of the
hexadecimal system. The first six letter of the alphabet are used for the remaining
six digits.
A=10, B=11, C=12, D=13, E=14, F=15
The hexadecimal system used in PLCs because it allows the statues of large
number of binary bits to the represented in a small space such as on a computer
screen or programming device display. Each hexadecimal digit represented the
exact of the four binary bits. To convert a decimal number to a hexadecimal
number the decimal number is divided by the base of 16.
To convert decimal 28, for example, to hexadecimal
Decimal 28 divided by 16 is 1 with a remainder 12. Twelve is equivalent to C in
hexadecimal. The hexadecimal equivalent of decimal 28 is 1c.
The decimal value of a hexadecimal is obtained by multiplying the individual
hexadecimal digits by the base 16 weight and the adding the results. In the
following example the hexadecimal number 2B is converted to its decimal
equivalent Of 43.

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COOMUNICATION
There are several methods to communicate between a PLC and programmer or
even between two PLCs. Communications between a PLC and a programmer (PC
or Hand held) are provided by the makers and you only have to plug in a cable
from your PC to the programming port on the PLC. The communication can be
RS232, RS485 or TTY. Communication between two PLCs can be carried out by
dedicated links supplied/ programmed by the makers (RS232 etc) or via outputs
from one PLC to the input on another PLC. The direct link method of
communication can be as a simple as, if an output on the PLC is on then the
corresponding input on the second PLC will be on and then this input is used within
on the program on the second PLC
PLC OPERATION
There are four basic steps in the operation of all PLCs. Which continually take
place in a repeating loop.
Input scan
Program scan
Output scan
Housekeeping

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Input Scan
Detect the state of all input device that are connect to the PLCs.
Program Scan
Execute the user create program logic.
OUTPUT SCAN
Energize or de-energize all output devices that are connect to the PLCs.
HOUSEKEEPING
This step includes communication with program terminals, internal diagnostic etc.
CHECK INPUT STATES
First the PLC takes a look at each input to determine if is on or off. In other words,
is the sensors connected to the first input on? Then second input? Then the third
so on…it record this data into its memory to be used during the next step.
EXECUTE PROGRAM
Next PLC executes your program one instruction at a time.
Maybe the program says that if the first input was on then it should on the first
output. Since it is already knows which input are on/off from the previous step it
will be able to decide whether the first output should be turn on based on state of
first input. It will store the execution result for use during the next step.
UPDATE OUTPUT STATES

26
Finally the PLC updates the state of the outputs. It update the outputs base on
which inputs were on during the first step and the result of executing your program
during the second step. Based on the example of step 2 it would now turn on the
first output because the first input was on and your program said to turn on the first
output when this condition is true.
After the third step the PLC goes back to step one and repeats the step
continuously. One scan time is defined as the time is takes to execute the 3 steps
listed below.

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 PROGRAMMING PLC
Various languages are used for programming of PLCs.
Ladder Diagram ( LD)
Ladder diagram is a graphic programming language derived from the circuit
diagram of directly wired relay control. The ladder diagram contains contact rails
to the left the right of the diagram, these contact rails are connected to switching
elements (normally open/ normally closed contacts) via current path and the coil
elements.

FUNCTION BLOCK DIAGRAM (FBD)

In the function block diagram, the function and blocks are represented graphically
interconnected into networks. The function block diagram originates from the
logic diagram for the design of electric circuits.

SEQUENTIAL FUNCTION CHART (SFC)

The sequential function chart is language resource for the structuring of sequence-
oriented control programs. The element of the sequential function charts are steps,
transition, alternative and parallel branching. Each step represents a processing
28
state of a control program, which is active or inactive. A step consists of action
which identical to the transition, are formulated in the IEC 1131-3 languages.
Action themselves can again contain sequence structure. The feature permits the
hierarchical structure of the control program. The sequential Function Chart
therefore an excellent tool for the design and structuring of control programs.

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 LADDER LOGIC
Ladder Logic, Ladder programs is the most common programming language used
to program a PLC.

Ladder Logic was one of the first programming approaches used in PLCs because
it borrowed heavily from the relay diagram that plant electricians already knew.
The symbols used in relay ladder Logic consists of a power rail to the left, a second
power rail to the right. The logic of each circuit (or rung) is solved to the left to
right. The symbols of these diagram look like a ladder with two side rails and
circuits that resemble rungs on ladder.
The picture above represented single “rung” of ladder
If input is on (or true)- power (logic) completes the circuits from the left rail- and
output turns ON(or true)
If output is off (or false)- then the circuit is not complete and logic does not follow
to the right- and output
1 is OFF
There are many logic symbols available in ladder logic-includes
Timers , counter , Math, and Data moves such that any logical condition or control
loop can be represented in ladder Logic. With just hand full of basics symbols – a
normally open contact, normally closed contact, normally open coli, normally
close coils, timer, counter most logical conditions can be represented.
CONTACT AND COILS
With just the normally open contact and normal open coil a surprising array of
basic logical conditions can be represented.

Normally open contact

This can be used to represent any input to the control logic- a switch or sensor, a
contact from an output, or an internal output.

30
When “solved” the reference input is examined for an ON (Logic1) condition. if it
is ON, contact will closed and allow power (logic) to flow from left to right. If the
state is off (logic 0).then contact is open, power (logic) will NOT from left to right.
Normally open coil
This can be used to represent any discrete output from the control logic

When “solve” if the logic to left of the coil is TRUE, the referenced OUT is ON
(logic1)
SOLVING SINGLE RUNG

Suppose a switch is wired to input, and a light bulb is wired through output 1 in a
such way that the light is OFF when output1 is off and ON when output1is ON.
When input1 is OFF (logic 0) the contact remaining open and power can’t flow
from left to right, therefore,Output1 remain off (logic 0)
When input is ON (logic 1) then the contact close, power flows from left to right,
and output1 becomes ON (the right turns ON)
THE AND RUNG
The AND is a basic fundamental logic condition that is easy to directly represent
in Ladder Logic.

Suppose a switch is wired to Switch1, a second switch is wired toSwitch2, and a

light bulb is wired through Light1 in such a way that the light is OFF when Light1
is OFF, and ON when Light1 is ON.
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In order for Light1 to turn ON, Switch1 must be ON, AND Switch2 must be ON.
If Switch1 is OFF, power (logic) flow from the left rail, but stops at Switch1.
Light1 will be OFF regardless of the state of Switch2.
If Switch1 is ON, power makes it to Switch2. If Switch2 is OFF, power cannot
flow any further to the right, and Light1 is OFF.
If Switch1 is ON, AND Switch2 is ON - power flows to Light1 solving its state to
ON.
THE OR RUNG
The OR is a logical that is easy to represent in ladder diagram

Suppose a switch is wired to switch 1, second switch is wired to switch 2, and

the light bulb is wired through a light1 in such a way the light is OFF when light
is OFF, and ON when light is ON. In this instance, we want to the light to turn ON
if either switch1 OR switch is ON.
If switch1 is ON - power flow to Light1 turning it ON.
If switch2 turn is ON – power flows through the switch2 contact, and up the rail
to light1- turning it ON.
If switch1 AND Switch2 are ON- light1 is ON.
The only way Light1 is OFF is if Switch1 AND Switch2 are OFF.

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MOTOR STARTER EXAMPLE:

First consider a hardwired approach

The following line diagram illustrate how a normally open and a normally closed
pushbutton might be connected to control a three -phase AC motor as shown above
figure.
In this example , a motor starter coil (M) is wired in series with a normally open,
momentary start pushbutton, a normally closed , momentary stop pushbutton , and
normally closed overload relay (OL) contacts.
Momentarily pressing the start push button complete the path for current flow and
energies the motor starter (M). This close the associated M and Ma (auxiliary
contact located in the motor starter ) contacts.
When the start button is released, current Continues to flow through the stop button
and the Ma contacts, and the M coil remains energized. The motor will run until
the normally closed stop button is pressed, unless the overload relay (OL) contacts

33
open . when the stop button is pressed, the path for current is interrupt , opening
the associated M and Ma contacts and the motor stop.

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 SCADA
Introduction
SCADA is not a specific technology, but a type of application
“SCADA” stands for Supervisory Control And Data Acquisition –any application
can gets data about a system in order to control the system is a SCADA
application’’ it is a purely software package that is positioned on top of hardware
to which it is interfaced , in general via Programmable logic controller (PLCs), or
other commercial hardware modules.
In other words
SCADA: the term refers to a large scale, distributed measurement (and control)
system. SCADA are used to monitor or to control chemical, physical or transport
process.
SCADA it is refers to an industrial control system a computer system monitoring
and controlling process. The process can be industrial, infrastructure or facility
describe below
Industrial process: it is includes those of manufacturing, production, power
generation, fabrication, and refining and process may be in continuous, batch,
repetitive or discrete or modules.
Infrastructure process: it may be public or private and water treatment and
distribution, wastewater collection, and treatment, oil and gas pipelines , electric
power transmission and distribution, and large communication systems.
Facility Process: it is occur both in public facilities and private ones, including
building, airports, ship and space station. The monitor and control HVAC, access
and energy consumption
A SCADA system usually consists of following subsystem
A Human – Machine interface (HMI) is the apparatus which present process data
to human operator, and through this, the human operator monitor and control the
process.
A supervisory (computer) system, gathering (acquiring) data on the process and
sending commands. Remote terminal unit (RTU) connection to sensors in the
process and converting sensors signals to digital data and sending digital data to
the supervisory system.
35
Programmable Logic Controller (PLC) used as field devices because they are more
economical, versatile, flexible configurable than special purpose -RTUs.
Communication infrastructure connection the supervisory system to the Remote
Terminal Unit.
Systems Concepts
The terms SCADA usually refer to a central system that monitors and controls a
complete site. The bulk of the site control is actually performed automatically by
a Remote Terminal Unit (RTU) or by a programmable Logic controller (PLC).
Host control functions are almost always restricted to basic site over- ride or
supervisory level capability.
EX: 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 condition, 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 performs of the loop.

36
TAGS (POINTS)
It is logical name of a variable or object that be used in our animation of a plant.
Tags are two types
System defined Tags
User defined tags
System defined tags
It is represent the system value in the SCADA it is represented by dollar sing $
User defined tags
This tag are defined by the user or programmer Except (A,S) are not defined.
Trends:
it is used for graphical representation of process
Two types
Real times trends
Historical Times trends

Classification of tags
Direct tags
Indirect tags
Direct tags
These tags are directly used by the programmer to represent the value of plant or
variable
Indirect tags
These tags are used by the another tags to show or represent the value of plant or
variable Direct tags
37
Memory tags : these tags having no connection with process the plant.

ALARM
An important part of most SCADA implementation is alarm handling. The system
monitors whether certain alarm conditions are satisfied, to determine when an
alarm event has occurred. Once alarm event has been detected, one or more action
are taken (such as the activation or remote SCADA operators are informed) in
many case, a SCADA operate may have to knowledge the alarm event, these may
be deactivate some alarm indicators whereas other indicators remain active until
the alarm conditions are cleared. Alarm conditions can be explicit - for example,
an alarm point is a digital status point that has either the value NORMAL or
ALARM that is calculated by a formula based on the values in other analogue and
digital points- or implicit: the SCADA system might automatically monitor
whether the value in an analogue point lies outside high and low limit values
associated with that point. Examples of alarm indicators include a siren, a popup
box on a screen, or a colored or flashing area on a screen (that might act in a similar
way to the "fuel tank empty" light in a car); in each case, the role of the alarm
indicator is to draw the operator's attention to the part of the system 'in alarm' so
that appropriate action can be taken. In designing SCADA systems, care is needed
in coping with a cascade of alarm events occurring in a short time, otherwise the
under lying cause (which might not be the earliest event detected) may get lost in
the noise. Unfortunately,
when used as a noun, the word 'alarm' is used
rather loosely in the industry; thus, depending on context it might mean an alarm
point, an alarm indicator, or an alarm event.
SYSTEM COMPONENTS
The three components of a SCADA system are:
Multiple Remote Terminal Units (Also knows as RTUs or outstation)
Central control Room with host computer (s)
Communication infrastructure

38
Remote Terminal Unit (RTU)
The RTU connects to physical equipment and read status dada such as the
open/close status from a switch or a valve, read measurements such as pressure,
flow, voltage or a valve, or setting the speed of a pump. The RTU can read digital
status data or analogue measurement dada, and send out digital commands or
analogue.
Salient feature of modern SCADA system
User- friendly (X-windows/graphic) interface.
Automatic control.
Off-line processing.
Integrated environments.
Extensive Historical data manipulation.
Extremely high data throughput
On-line complex electrical network analysis.
Real time supply/ demand- side economic calculations.
Automatic voltages and power factor correction.
10.Distributed processing power.

39
 Benefits HMI/SCADA
1. Powerful monitoring and control over your production
2. Ease of use for New and experienced users.
3. Robust connectivity to other software, system and devices
4. True client /server Architecture for ease Scale ability Powerful thin client
technology.
Sophisticate Alarm and trending.
SCADA Recommended
LAN /WAN support
Import from multiple PLC system 3. Support for low bandwidth operation.
Secure & flexible.
Low CPU & memory requirements.
Drives work on Rs232, 422, 485, TCP/IP.
Unlimited number of tags (tags support 80 char).
Graphic (transparent color support, advanced animation without coding, import
graphic window bitmap – Auto Cad, fax image.
Supervision
Controlling
Dada collection
12. Interface of PLCs
13. Alarm.

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 Human Machine Interface (HMI)
Introduction
HMI is the smallest form of SCADA which is used for monitoring and controlling
and it is combination of hardware and software.
Human machine Interface:
The HMI/SCADA industry was essentially out of a need for user friendly front-
end to a control system containing programmable logic controller (PLC). While a
PLC does provide automated, preprogrammed control over a process, they are
usually distributed across a plant, making a difficult to gather data from them
manually. additionally, the PLC information are usually in crude user-unfriendly
format. The HMI/SCADA gather information from the PLCs via some form of
communication method, and combines and formats the information. Since the
early1990s the role of SCADA system in large civil engineering solutions has
changed, requiring them to perform more operations automatically. A
sophisticated HMI may also be linked to a database to provide instant trending
diagnostic data, scheduled maintenance procedures, logistic information, detail
schematics for a particular sensors or machine, expert –system troubleshooting
guides. Since about 1998 , virtually all major PLC manufacture
have offered integrated HMI/SCADA system, many of them using open and non
proprietary communication protocols.

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 Types of HMI
Keypad
Touch screen
Keypad + touch screen
Difference between SCADA and HMI
SCADA HMI

It is software it is combination of s /w and h/w

It is work at low temperature it is work at high temperature & low

Screen ratio of SCADA is large Screen ratio of HMI is Low i.e 6 inch

Local and Remote control LAN area Control

Data base connectivity is possible Data base connectivity is not possible

Range of SCADA Range of HMI is 100m

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 Instrumentation
Instrumentation is a branch of engineering electric (science) which is used for
measurement of process parameters and electric parameters it include, flow meter,
thermocouple, level instrument etc.
Transducer:
It is device which converted one form of engineering into another form of energy.
Sensors:
It is transducer which converted one form of energy into measurable form of
energy.
Types of sensors
Flow meter
Pressure sensors
Ambient meter
Transmitter
It is a device which is used for the transmission of signal over long distance so
generally used for transmitter.

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Electric power generation, transmission and Distribution.
Manufacturing industries.
Mass transit & whether management system
Traffic signals.
Cement and petrochemicals industries.
Automobiles industries

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Application for PLC in substation automation & SCADA
There are many applications for PLC for substation automation, distribution
automation & SCADA system. As utility engineers become more familiar with
capability of PLCs and PLC manufactures develop a new substation specific
products. The number and type of potential applications continues to increase.
RTU (Remote terminal Unit) emulation & replacement
Alarm reduction & intelligent messaging
Utilize existing SCADA protocols
Ethernet, TCP/IP
Multiprotocol, DNP 3.0, Modbus plus
Analog & Discrete I/O
Protection & control
Protective relay interface/ intrection
Automatic switching
Automatic transfer schemes
Circuit breaker control &interlocking
Feeder automation & fault recovery
Automatic service restoration
Emergency load Shedding
Station HMI- Graphic user interface (GUI)
Remote control
Demand control

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 CONCULAION
This report has discussed the role that programmable logic controller have in
efficient design and control of mechanical process. Also discussed was the
understanding, AUTOMATION, SCADA, HMI, Instrumentation and the
programming involved with it. Finally, the report has discussed as complete
Automation, like a , relay, Components, history. Programmable Logic Controller,
history, advantages. Inside PLC etc…PLC components, understanding Ladder
logic, example SCADA: this section contains basic introduction of SCADA,
features, Recommended, Tags, Trends Difference between SCADA &
HMI.HMI: This section contains basic HMI, types of HMI, introduction.

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 REFERANCE
Pollet, Jonathan, SCADA Security Strategy, Plant data Technology, August 8,
2002
www.scadanews.com
www.princeton-indiana.com/wasetewater/Pages
www.ref.web.cern.ch/ref/CERN
www.sss-mag.com/scada.html www.scada.com
www.scrib.com

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 BIBLIOGRAPHY
Study material by Prolific automation system pvt. Ltd.
Study material by Futronix automation pvt. ltd. Programmable logic by John. R .
Hockwarth controllers
Programmable logic by L.N.Bryan controllers E.A.Bryan
Programmable logic by W.Batton
Controllers
Automatic manufacturing by Hugh Jack
System with PLC
Communication technology guidelines for SCADA system, power delivery by
Marihart, D.J

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