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    01 Industrial Automation Controllers

    Uploaded by

    Nirjhar Bhatnaagar
    This document provides an overview of an online industrial automation class covering Programmable Logic Controllers (PLCs) and SCADA systems. The class is divided into 3 modules that will cover industrial field instrumentation and controllers, PLCs using the ABB AC500 system, and the SCADA/HMI system Ni-LabVIEW. Examples of process control topics that will be discussed include temperature control, level control, pressure control and flow control. The class will also explore common control system components like sensors, transducers, setpoints, process variables, controllers, actuators and more. Hands-on experience with an industrial pilot plant is included.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    01 Industrial Automation Controllers

    Uploaded by

    Nirjhar Bhatnaagar
    63 views29 pages
    This document provides an overview of an online industrial automation class covering Programmable Logic Controllers (PLCs) and SCADA systems. The class is divided into 3 modules that will cover industrial field instrumentation and controllers, PLCs using the ABB AC500 system, and the SCADA/HMI system Ni-LabVIEW. Examples of process control topics that will be discussed include temperature control, level control, pressure control and flow control. The class will also explore common control system components like sensors, transducers, setpoints, process variables, controllers, actuators and more. Hands-on experience with an industrial pilot plant is included.

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    This document provides an overview of an online industrial automation class covering Programmable Logic Controllers (PLCs) and SCADA systems. The class is divided into 3 modules that will cover industrial field instrumentation and controllers, PLCs using the ABB AC500 system, and the SCADA/HMI system Ni-LabVIEW. Examples of process control topics that will be discussed include temperature control, level control, pressure control and flow control. The class will also explore common control system components like sensors, transducers, setpoints, process variables, controllers, actuators and more. Hands-on experience with an industrial pilot plant is included.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    63 views29 pages

    01 Industrial Automation Controllers

    Uploaded by

    Nirjhar Bhatnaagar
    This document provides an overview of an online industrial automation class covering Programmable Logic Controllers (PLCs) and SCADA systems. The class is divided into 3 modules that will cover industrial field instrumentation and controllers, PLCs using the ABB AC500 system, and the SCADA/HMI system Ni-LabVIEW. Examples of process control topics that will be discussed include temperature control, level control, pressure control and flow control. The class will also explore common control system components like sensors, transducers, setpoints, process variables, controllers, actuators and more. Hands-on experience with an industrial pilot plant is included.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    You are on page 1of 29

    Industrial Automation with

    PLC & SCADA (IAD101)

    Online class
    Arumugam J
    Industrial Automation group
    NIELIT Calicut
    IAD101 : Industrial Automation with PLC & SCADA
    12th Batch (17th May 2022)

    S.No. Module Title

    1 Industrial Field Instrumentation & Controllers

    2 Programmable Logic Controllers(PLC) [ABB AC500]

    3 SCADA / HMI (NI-LabVIEW)

    NIELIT Calicut Industrial Automation 2


    Thermal power station

    NIELIT Calicut Industrial Automation 3


    NIELIT Calicut Industrial Automation 4
    Setpoint, or SP Common Control system terms:
     Process
     Primary Sensing Element (PSE)
    PV
    CV  Transducer / Transmitter
     Lower-Range Value and Upper-Range Value
    LRV (Zero - 0%) & URV(Full Scale - 100%)
     Span

     Process Variable or PV
     Setpoint or SP
     Controller
     Manipulated Variable (MV) or CV
    (Temperature Control, Level Control  Final Control Element (FCE) / Actuator
    Pressure Control, Flow Control etc…)
     Lower-Range Value and Upper-Range Value
    LRV (Zero - 0%) & URV(Full Scale - 100%)
     Span

     Manual mode & Automatic mode


    NIELIT Calicut Industrial Automation 5
    Pilot Plant @ NIELIT Calicut

    NIELIT Calicut Industrial Automation 6


    Why do we need Process Control?

     Safety: The primary purpose of a Process Control


    Advantages of Industrial Automation
    system is safety:
     Personnel safety Improved safety
     Environmental safety
    Increased productivity
     Equipment safety
     Quality: Improved product quality

    Process control systems are central to maintaining Reduced labor or production cost
    product quality.
    Reduced routine manual tasks
     Profit:
    The real challenge in process control is to do so Assisted remove monitoring

    safely without compromising product quality.


    NIELIT Calicut Industrial Automation 7
    Types of Industrial Automation
     Fixed type of automation (Hard Automation):
    Manufacturing facilities perform routine, repetitive tasks that do not change from product to product
    challenging to modify the process or reconfigure the equipment.
    Example: Assembly lines in the automotive industry.
     Flexible Automation (Soft Automation):
    Allows for more flexible production
    Similar to programmable automation in that it provides flexibility for product changeovers.
    Example: CNC machines. (Computer Numerical Control)
     Programmable type of automation:
    The manufacturing tasks are handled by a computer program that delivers specific instructions to the machines.
    The control program can be reprogrammed for each batch.
    Example: Industrial robots.
     Integrated Automation:
    Integrated automation is entirely handled by computers and control processes with minimal human
    involvement. Computers can design the necessary parts, test the designs, and fabricate the parts.

    NIELIT Calicut Industrial Automation 8


    Automation Pyramid

    SCADA / HMI

    Control Level Devices


    (PLC / PID Controllers)

    Production Floor
    Sensors & Actuators

    NIELIT Calicut Industrial Automation 9


    Identify the Field Instruments &
    2 Control the Process

    1 3 Process:
    1. If LS2 is TRUE (1)
    4 STOP -> PUMP & OPEN -> SV
    2. If LS1 is TRUE (1)
    CLOSE -> SV & RUN -> PUMP
    3. If the LEVEL is above 65%
    Stirrer (Mix) - ON
    5 6

    NIELIT Calicut Industrial Automation 10


    2

    As per controller - Signals


    1 3
     Digital
    4
    Input (DI) - 44 & 55
    Output (DO) - 1,3
    1 3 & 66
     Analog
    Input (AI) - 22
    5
    Output (AO) - Nil

    NIELIT Calicut Industrial Automation 11


    As per controller - Signals
     Digital
    Input (DI) - 44 & 5 5
    Output (DO) - 33 & 66
     Analog
    Input (AI) - 2 2
    Output (AO) - 11

    NIELIT Calicut Industrial Automation 12


    Process Plant

    Controllers
     Microcontrollers
     Arduino
     Raspberry Pi
     ARM controllers
     DAQ Systems
     PLC
     PAC
     DCS etc….

    NIELIT Calicut Industrial Automation 13


    Process Plant control
    with Discrete signals

    DO
    1 DO
    3

    4 Controller
    DI

    5
    DI 6 DO

    NIELIT Calicut Industrial Automation 14


    Analog Signals

    NIELIT Calicut Industrial Automation 15


    Prepare system study Report (Table)

     Name of the field Instruments


     Type of the signal
     Physical signal range
     Electrical signal range
     P&ID symbol etc..

    NIELIT Calicut Industrial Automation 16


    Prepare system study Report:

    NIELIT Calicut Industrial Automation 17


    PLC - Introduction
    Kinds of PLC

    1) Compact (Fixed) PLC

    2) Modular PLC
    (Siemens 300,ABB 500 & AB SLC 500)

    3) PC Based Controllers
    (Siemens WinAC)

    NIELIT Calicut Industrial Automation 19


    Compact (Fixed IO) PLC

    NIELIT Calicut Industrial Automation 20


    Modular IO PLC

    NIELIT Calicut Industrial Automation 21


    PC Based Controllers

    NIELIT Calicut Industrial Automation 22


    Hardware / Architecture of a PLC
    1) Power Supply
    2) CPU & Memory (Data & Program )
    3) I/O Modules

    NIELIT Calicut Industrial Automation 23


    PLC Scan Cycle (Cyclic execution)

    NIELIT Calicut Industrial Automation 24


    PLC Program SCAN cycle

    NIELIT Calicut Industrial Automation 25


    Top PLC Manufactures

    NIELIT Calicut Industrial Automation 26


    Programmable Logic Controllers (PLC)

    AC500
    Powerful PLC featuring a wide range of performance, communications and I/O capabilities for industrial
    applications. The ideal choice for complex, high speed machinery and networking solutions.

    AC500-eCo
    This compact PLC is offering optimally suited flexible and economical configurations for automation solutions in
    smaller applications.

    AC500-S
    This safety PLC (SIL3, PL e) is designed for safety applications involved in factory, machinery or process automation
    area. The ideal choice to implement and manage complex safety solutions.

    AC500-XC
    Extreme Condition PLC variant of the AC500 platform with extended operating temperature, immunity to vibration
    and hazardous gases, use at high altitudes and in humid environments.

    NIELIT Calicut Industrial Automation 27


    AC500
    AC500-S Safety PLC (SIL3)

    AC500-eCo
    AC500-XC

    NIELIT Calicut Industrial Automation 28


    https://store.codesys.com/en/codesys-development-system-v2-3.html

    CODESYS is the leading software platform for IEC 61131-3 compliant project engineering (PLC)

    NIELIT Calicut Industrial Automation 29

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