GENERAL INTRODUCTION TO DISTRIBUTED CONTROL SYSTEM ( DCS )

 Discussion about the various input/output signals in industries.

 Overview about the PLC and SCADA systems.

 General comparison between the PLC and DCS.

 Evolution of the Distributed Control System.

 Comparison between the Local Control architecture and DCS architecture.

 Description about the RTU and LCU and comparison.

 Application of Distributed Control Systems.

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DISTRIBUTED CONTROL SYSTEMS

TYPE 1 (ABB 800xA DCS)

ARCHITECTURE OF ABB DCS CONTROLLER:

 Introduction to the general architecture of the AC800M controller.

 Comparison of the general architecture of the AC800M controller with the

lab specific configuration.

 How to do the addressing for the various nodes connected to the AC800M
controller.

IP CONFIGURATION SETTINGS FOR ABB AC800M CONTROLLER

 Identify the IP address of controller in a running plant.

 Set the IP address for the new controller.

WORKING WITH CONTROL BUILDER PROGRAMMING TOOL SOFTWARE.

 Developing the programs in LD and FBD languages.

 Creation of Global and Local variables.

 Creation and utilization of function block and hardware libraries.

 Creation of new control modules and working with predefined control modules.

 Creation and utilization of user defined function block and data types.

 Working in simulation mode.

 Hardware configuration.

 I/O configuration.

 I/O Forcing.

 Transferring project to controller.

 Simulate hardware for SCADA interfacing.

DEMONSTRATION AND EXPLANATION ABOUT THE REDUNDANCY FEATURES OF

AC800M CONTROLLER

 Controller CPU redundancy.

 External hardware redundancy.

 I/O Modules redundancy.

 Communication port redundancy.

 Communication Line redundancy.

 Server redundancy.
EXPLANATION AND APPLICATION OF COMMUNICATIONS PROTOCOLS FOR
AC800M CONTROLLER.

 Communication to the I/O modules using Electrical and Optical module bus.
 Third party device connectivity using ModBus protocol.
 Control Builder communication through
Ethernet.
 Configuration of PROFIBUS DP master and
slaves.

EXPLANATION AND WORKING WITH VARIOUS PID CONTROL MODULES.

 Details about the various loops.

 PID Control through Control Builder.

HOW TO CREATE BACKUP OF THE PROJECTS AND TO RESTORE THE PROJECTS.

 Create project backup in a system on the network.

 Restore the projects from backup option.

TROUBLESHOOTING

 Troubleshoot AC 800M hardware.

 Troubleshoot PROFIBUS and Module Bus communication to the S800 I/O’s.

 Trace signals in Control Builder applications using different programming

techniques.
 INTRODUCTION AND WORKING WITH MAN MACHINE INTERFACE.

 MMI Introduction.
 Slave station and I/O addressing.
 MMI Main screen design and multi screen creation.
 Applications.
 Alarms.
 Passwords.
 Trends.
 Recipes.
 Download and Upload MMI screen design.
 MMI and Controller Interfacing.
 Enabling of Modbus connection between controller and MMI.
 Read the data from MMI.
 Write the data to MMI.

DESIGNING, MONITORING & CONTROLLING OF PROCESSESS USING

ENGINEERING AND OPERATOR WORKPLACE

 Setup the OPC connectivity to AC800M.

 Plant Explorer workplace, Engineering Workplace, Operator Workplace.
 Navigate in the system and create new object/aspect.
 Configure Faceplates, Graphic displays and Graphic element.
 Creating the Objects & Point
 Interfacing controller variables with SCADA
 Points Design the plant in SCADA
 Creating the face element and face plate
 Monitor and control the plant in SCADA
 Applications
 Trend
 Alarm
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 Distributed Control Systems
TYPE 2
(Siemens PCS7 DCS)

SIMATIC S7 Manager Hardware Configuration Wizard for PCS 7

 Create Plant Hierarchy & Functional Diagram for Training project using CFCs

 Add control block and remaining logic to CFCs

 Compile & Download and Add Simulation Logic and Test Logic

REMOTE I/O CONFIGURATION OF PROFIBUS –DP [ET200S] INTERFACE MODULE

 S7 Manager Hardware configuration in Profibus – DP bus.

 Add ET200s Interface Module Create CFCs

 Add Digital input and output Channel Drivers and monitoring.

 Priority levels – run-time behavior of Controller Working with PCS 7 Basic Libraries
and Blocks

STEP FUNCTION CHART – THE SEQUENCER

 Build a step sequence and connect I/Os Representation in CFC

 Modes and Trouble- shooting

 Interface to WinCC and SFC Visualization

NETWORKING WITH NETPRO

 Communication Objects in NetPro S7 controller and WinCC Station Functionality

of the NetPro Tool

 Communication types and their Properties

 Setup Various Communication types and Compile & Download

WINCC GRAPHICS FOR PLANT AUTOMATION

 Graphics Elements and Symbol dynamics and Faceplates Block Icons and
Bulk Engineering on Tag Connections Setting Impacting the performance

 Create WinCC screens for the training Process Plant Automation

DISTRIBUTED ET 200M FIELDBUS & I/O SYSTEM IN PROFINET

 Properties of S7 CPU of PROFINET bus and Add Redundancy Feature Remote I/O
Modules Engineering an Analog Input and Analog Output from the Module to the
screen.

 Working with PID control system.

WinCC Graphic Design for PID control in Operator Station

WinCC Archives, Alarms and Trends

Tag Logging

Trends (Online trend, Archive trend and Pre- Configuration of

Trends) Alarm Logging (Alarm classes, Status Texts and Filter
for operator) Storage (Tag logging storage and Alarm logging
storage
 SIMATIC PDM (PROCESS DEVICE MANAGER)

Overview of Process Device Manager SIMATIC PDM

Engineering Device Integration and Parameter
View.

Asset Management and Informative Online

Displays Practical Functions, Life list and
Design

CONFIGURATION OF HART DEVICE INTERFACE

Recording of Structures of HART multiplexer networks

Configuration Rosemount 2051 Pressure Transmitter using HART

PROTOCOL Graphical design and configuration in operator
station

Device Description Language (DDL)

CONFIGURATION OF FOUNDATION FIELDBUS DEVICE INTERFACE

Configuration in Profibus – DP bus Add IM- 153-2 FF link & IM 157 FDC
(Field Device Coupler)

Configuration of FOUNDATION Fieldbus H1 (FF) with

SIMATIC PCS 7 Configuration Control in the Field (CiF) and Link
Active Scheduler (LAS) PID closed-Loop Control in the AS / FF
– Segment
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DISTRIBUTED CONTROL SYSTEMS

( TYPE 3
HONEYWELL EXPERION DCS)

Introduction about Honeywell DCS and its Overview

 Overview of DCS.
 Difference between Honey well C200E & other controllers available.
 Architecture of C200E in detail.
 Overview of different interface modules available in C200E.

Real time configuration and working with basic instruction on hybrid controller HC-900

 Configuration of inputs and outputs.

 Developing program in hybrid control designs and online monitoring.
 Downloading and uploading procedure in hybrid control designs.
 Giving assignment.

Live configuration of DCS and its different Input/output modules available

 Brief Introduction about Experion process knowledge system LS.

 Configuration of fault tolerance Ethernet Bridge (ETE).
 Configuration of C200E.
 Configuration of different I/O modules available.

Development of logic & online monitoring in control module

 Configuration of control module.

 Developing different logic in control module base on FBD.
 Downloading and uploading of programs.
 Online monitoring of control module.
Configuration of Input/output channel and working with special instruction

 Real time I/O channel configuration.

 Developing various program based on special instruction such as logical utility.
 Math operation
 Auxiliary function
 Assignment based on special instructions.

Execution of different control algorithm available

 Detailed theory about proportional integral derivative.

 Detailed overview of control loop methods.
 Real time configuration of PID.
 Execution of PID with different models.

Developing the animation screen for monitoring and controlling the remote process

 Brief explanation about SCADA.

 Creating the channel, controller, and points through quick builds.
 Creating the animation screen using HMI web display builder.
 Motoring the process designed through station.

Developing different application in SCADA for monitoring the process

 Creating the faceplate.

 Configuration of trend for various parameters.
 Configuration of alarm for various process
 Assignment based on Industrial Application.

Development of script & working with some advanced application

 Configuration of script for different process

 Interfacing Experion PKS with Microsoft excel through dynamic

exchange.
 Configuration and execution of Honeywell temperature controller

 Configuring the model.

 Execution of model with different models such as P / PI / PD / PID

Quality Checking Of Auto Components Based On Pressure Fit Assembling System

Using Load Cell Using Honeywell DCS

 Configuration of analog module.

 Calibration of load cell.

 Separation of defected and non defected objects.

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 Programmable Logic Controller
Programmable Logical Controller ( PLC )
(PLC)
Allen Bradley / ABB Training
/ Siemens
Allen / Content
Bradley Keyence
/ Omron/ Omron / GE-Fanuc

Introduction of PLC software and addressing of Input / output system

• Specification and features of PLC

• Addressing of input / output system and memory mapping
• Live practice on PLC programming tools software
• Assignment based on real time applications

Explain the application of timer [delay function] in automation industries

• Explain the role of timer in industries

• Various types of timer and its application
• Programming based on timer and live practice in PLC software
• Assignment based on timer applications

Explain the usage of counter function in automation industries

• Differentiate the timer & counter function in PLC software and its usage
• Various type counter and its application.
• Programming based on timer / counter and live practice in PLC software
• Assignment based on counter applications

Upload / download the program and online monitoring in PLC Control panel

• Communication detail between PLC and programming tool software in PC Procedure of

upload / download the program in PLC
• Online monitoring and practice of programming tools software in PLC panel

Industrial standard of PLC panel Erection, commissioning & Trouble Shooting

• Basic requirement of PLC panel designing and its apparatus tools

• Draw the electrical wiring diagram of Keyence PLC panel and trouble shooting.
• Explain the [ source/sink ] type of digital input /output
• Assignment based on electrical wiring on PLC panel used in industrial application

Live practice on PLC panel wiring and application development

• Examining the field input devices to PLC panel

 • Verifying the field output devices from the PLC panel
• Design and development of real time industrial
• Assignment based on complete PLC project solution

Supervisory Control And Data Acquisition

Supervisory Control & Data Acqisition ( SCADA )
(SCADA)
Training Content
Intellution /Wonderware
Wonderware /Intouch
Win CC

Introduction of SCADA system & design the industrial Application development

• Evolution of operator monitoring and control in automation industry

• Describe the data acquisition system (DAS) and (MMI)
• Various type of SCADA system in industries
• Explain the live demo application in SCADA system
• Explain the functional block diagram of SCADA system and its feature and application

Explain data base creating tag name creation and simulator drive addressing Method in SCADA
System

• Explain the role of data base and tag name in SCADA system
• Explain SCADA time, data link graphical design window & run time window
• Explain simulator drive address and I/O drive details
• Explain the communication details between PLC and SCADA systems
• Explain the type of signal tags and differentiate the digital input / digital output, Analog input /
analog output

Design & implementation of graphical display & its dynamic properties in SCADA System

• Explain the dynamic properties [Blinking, visibility, movement, filling]

• Live design practice on various industrial application monitoring window
• Explain the macro editor and script programming
• Assignment based on SCADA development screen

Explain alarm / event configuration and real time trends [graph] monitoring In SCADA System

• Explain alarm / even configuration

• Explain the usage of alarm and types of alarm and its application
• Explain the real time trend and type and configuration
 • Assignment and lab practice on alarm event and real time Trend monitoring

Interfacing of PLC panel to SCADA SYSTEM

• Communication parameter setting between PLC and SCADA

• PLC input /output and memory mapping for real time tag creation in SCADA
• Communication cable details and protocol information
• Assignment based on industrial application

Historical & real time trends monitoring and alarm events configuration

• Explain alarm event configuration

• Explain real time trend display
• Explain historical display configuration
• Assignment based historical display application

SCADA script programming and ODBC [using MS-ACCESS] & DDE [using MS-EXCEL] Connectivity in
INTOUCH SCADA

• Explain SCADA script programming

• Explain DDE [Dynamic Data Exchange using MS-EXCEL] connectivity
• Explain ODBC [Open Database Connectivity MS-ACCESS] connectivity
• Assignment based on DDE & ODBC connectivity

Recipe management and I/O drive configuration

• Explain recipe management system and configuration

• Live practice & assignment based on recipe management system
• I/O drive configuration and its procedure
• Various example of industrial application using recipe management system
 Man Machine Interface
(MMI)

o HMI Screen Designing

o HMI Programming

o Upload / Download

o MMI, PLC Interface

o Working Application in MMI

Variable Frequency Drive

(VFD)

o Basics of induction motors

o Basics of converters

o Handling of parameters with BOP, AOP

o PC-Tools Drive Monitor and Starter

o Commissioning of V/f-characteristics and vector control

o Handling of the free programmable terminals (BiCo)

o Special functions like DC-Braking

o Faults and Alarms

o Practical exercises at training case