INDUSTRIAL AUTOMATION

MID TERM INDUSTRIAL TRAINING

REPORT
ON
INDUSTRIAL AUTOMATION
HEALD AT

ShapMyskills Pvt. Ltd

SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENT FOR THE

AWARD OF THE DEGREE OF

BACHELORS OF TECHNOLOGY
(ELECTRICAL ENGINEERING)

SUBMITTED BY:
Aslam Ansari(2000240)

AMRITSAR GROUP OF COLLEGES, AMRITSAR, PUNJAB

January 2024

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CANDIDATE’S DECLARATION CERTIFICATE

I hereby certify that the work which is being presented in report entitled Industrial Automation by
ASLAM ANSARI in partial fulfillment of requirements for the award of degree of B. Tech (Electrical
Engineering ) submitted to I.K.G. Punjab Technical University, Department of Electrical Engineering at
Amritsar Group Of Colleges, Amritsar, Punjab under I.K.G. PUNJAB TECHNICAL UNIVERSITY ,
JALANDHAR is an authentic record of my own work carried out during a period from January 2024 to
June 2024 under the supervision of RANU SHARMA.

Signature of the student

Aslam Ansari

This is to certify that the above statement made by the candidate is correct to the best of my/our
knowledge.

Signature of the Supervisor(s)

Ranu Sharma

Signature of H.O.D
Namrata Kad

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ABSTRACT
This paper describes how the present automation system comes in to existence through its various stages.
In the past, system is done through relays and contactor logics. Since the human intervention is more,
the Scope of errors was also more. But with the advent of microprocessors Several new tools as PLC’s,
SCADA, and DCS come in to use. These have reduced human intervention, which in turn has increased
Accuracy, precision and efficiency. A comparative study has been Shown to justify why we have to
switch to present technologies.

Automation is the key to modernization and has been conceptually understood as a way to increase
efficiently and to improve productivity The process of having machine follow a predetermined sequence
of operation with little or no human labor, using special equipment and devices that perform and control
manufacturing processes is known as automation. The goals of automation are Integration of various
aspects of manufacturing operations to reduce labor cost, To improve productivity or efficiency, To
improve quality, To reduce human involvement therefore human error, To reduce work piece damage
that manual handling caused, To raise the safety level. The fundamental constituents of any automated
process are(1) a power source,(2) a feedback control mechanism, and (3) a programmable command (as
shown in figure structure. For example, an automated car wash typically completes its task with no
continuous or final assessment of the cleanliness of the automobile.

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ACKNOWLEDGMENT
I am highly grateful to the Namrata Kad ,HOD EE,, Amritsar Group of College, Amritsar, for providing
this opportunity to carry out the six-month industrial training at ShapMyskills Pvt. Ltd.

I would like to express my gratitude to other faculty members of Electrical Engineering Department of
AGC, Amritsar for providing academic inputs, guidance & encouragement throughout the training
period.

The author would like to express a deep sense of gratitude and thank RANU SHARMA Director/
Incharge of Company, without whose permission, wise counsel and able guidance, it would have not
been possible to pursue my training in this manner. The help rendered by SAPNA KUMARI Supervisor
for experimentation is greatly acknowledged. Finally, I express my indebtedness to all who have directly
or indirectly contributed to the successful join my industrial training.

Aslam Ansari
2000240

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TABLE OF CONTENTS

1. Introduction to Industrial Automation……………………………………………...............06-09

2. PLC……………………………..………………………………………………….……….10-11
3. Architecture of PLC…...……………………………………………………….….………..12-13
4. Ladder Diagram..…………………….……………………………………………...……...14-20
5. Programming By Ladder Diagram………………………………………………….……...21-24
6. Application of PLC…………………………………………………………………….........…25
7. SCADA…… ……………………………………………………………………….…….……26
8. SCADA Software……………………………………………………………………………....27
9. Architecture of SCADA………………………………………………………………….…26-35
10. Application of SCADA……………………………………………………………………..35-36
11. V.F.D………………………………………………………………………………………..36-39
12. Conclusion…………………………………………………………………………………...…40
13. Reference…………………………………………………………………………………….…41

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Introduction to Industrial Automation

An industrial production process consists of series of machines, through which a combination of raw
materials goes through and transform into the final product. Here, the term “machine” can be anything
like a motor, drill, conveyor belt, etc. which come under electromechanical devices or chemical
machines like ovens, dryers, chemical combustion systems etc.

Today, Industrial Automation has taken over the production process in industries and it is very difficult
to imagine a production line without automation systems. There are several factors that lead to the
implementation of automation system in industrial production like requirement of high-quality products,
high expectations in product reliability, high-volume production etc.

Industrial Automation is a process of operating machines and other industrial equipment with the help
of digital logical programming and reducing human intervention in decision making and manual
command process with the help of mechanized equipment. The term Automation is coined by an
Engineer from Ford Motor Company, who were pioneers in industrial automation and manufacturing
assembly line. In the beginning, the industrial production process is based on the eyes, hands and brain
of a worker, in contrast to modern day sensors, actuators and computers.

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The modern form of automation took shape during the Industrial Revolution in the 1800s when
automated processes and tools were used to increase factory productivity. Use of electricity in the1920s
led to faster production process at the factory changing the factory floor dynamics.

In 1771 Richard Arkwright invented the first fully automated spinning mill driven by water power,
known at the time as the water frame. An automatic flour mill was developed by Oliver Evans in 1785,
making it the first completely automated industrial process.

The Industrial Automation Market is expected to reach its peak size between 2023 and 2030. The global
industrial automation market was valued at 191.89 billion U.S. dollars in 2021 and is expected to grow
to 395.09 billion U.S. dollars in 2029, at a compound annual growth rate (CAGR) of 9.8% during the
forecast period.

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In addition to this, automation in the process of manufacturing has been significantly advanced to be
autonomous. It should be noted that the future potential of automation is aimed at eliminating the
repetitious and hazardous job roles by facilitating the outsourcing of the same to a machineThe number
of new jobs created by the industry is growing at a rate of 9% per year. In both technology and
manufacturing, automation is a rapidly expanding field. As technology advances, it is possible that more
and more tasks will be automated. As a result, demand for automation experts may increase.

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PLC ( Programmable Logic Controller )

PLC ( Programmable Logic Controller ) :

A programmable logic controller (PLC) is a small, modular solid state computer with customized
instructions for performing a particular task. PLCs, which are used in industrial control systems (ICS)
for a wide variety of industries, have largely replaced mechanical relays, drum sequencers and cam
timers.

A programmable logic controller, PLC, or programmable controller is a digital computer used for
automation of typically industrial electromechanical processes, such as control of machinery on factory
assembly lines, amusement rides, or light fixtures. PLCs are used in many machines, in many industries.

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In the 1960's Programmable Logic Controllers were first developed to replace relays and relay control
systems. Relays, while very useful in some applications, also have some problems. The primary reason
for designing such a device was eliminating the large cost involved in replacing the complicated relay
based machine control systems for major U.S. car manufacturers. These controllers eliminated the need
of rewiring and adding additional hardware for every new configuration of logic. These, along with other
considerations, led to the development of PLCs. plc was more improved in 1970's. In 1973 the ability to
communicate between PLCs was added. This also made it possible to have the controlling circuit quite
a ways away from the machine it was controlling. However, at this time the lack of standardization in
PLCs created other problems. This was improved in the 1980's. The size of PLC was also reduced then,
thus using space even more efficiently. The 90's increased the collection of ways in which a PLC could
be programmed (block diagrams, instruction list, C, etc.).

A programmable logic controller (PLC) is an industrial computer control system that continuously
monitors the state of input devices and makes decisions based upon a custom program to control the
state of output devices. It is designed for multiple inputs and output arrangements, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact. They are used in many
industries such as oil refineries, manufacturing lines, conveyor systems and so on, wherever there is a
need to control devices the PLC provides a flexible way to "soft wire" the components together. The
basic units have a CPU (a computer processor) that is dedicated to run one program that monitors a series
of different inputs and logically manipulates the outputs for the desired control. They are meant to be
very flexible in how they can be programmed while also providing the advantages of high reliability (no
program crashes or mechanical failures), compact and economical over traditional control systems.

In simple words, Programmable Logic Controllers are relay control systems put in a very small package.
This means that one PLC acts basically like a bunch of relays, counters, timers, places for data storage,
and a few various other things, all in one small package.

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ARCHITECTURE OF PLC:

The PLC give output in order to switch things on or off. The PLC's output is proportionally activated
according on the status of the system's feedback sensors and input terminal which is connected to PLC.
The decision to activate output are based on logic programmes. The logic programme stored in RAM or
ROM memory.

The PLC also have same as computer, a CPU, data bus and address bus to communicate with external
devices such as programmers, display monitor The next diagram shows a simplified diagram of PLC's
structure. The central processing unit control everything according to a programme stored in a memory
(RAM/ROM). Everything is interconnected by two buses, the address bus and data bus.

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Ladder Diagram (LD):

The Ladder Diagram is also a graphics oriented programming language which approaches the structure
of an electric circuit. Ladder Diagram consists of a series of networks. Each network consists on the left
side of a series of contacts which pass on from left to right the condition "ON" or "OFF" which
correspond to the Boolean values TRUE and FALSE. To each contact belongs a Boolean variable. If
this variable is TRUE, then condition pass from left to right.

Fig: ladder diagram

COMMUNICATION/PROGRAMMING WITH SOFTWARE RSLINX

This chapter explains how to program the PLC. It describes how to write a program, how the program
is structured and representation of the programming language.

PROGRAMING BY LADDER DIAGRAM:

Ladder logic is a method of drawing electrical logic schematics. It is now a graphical language very
popular for programming Programmable Logic Controllers (PLCs). It was originally invented to
describe logic made from relays. The name is based on the observation that programs in this language
resemble ladders, with two vertical "rails "and a series of horizontal "rungs" between them. A program
in the ladder logic, also called ladder diagram is similar to a schematic for a set of relay circuits.

The Ladder Diagram is also a graphics oriented programming language which approaches the structure
of an electric circuit. The Ladder Diagram consists of a series of networks. A network is limited on the
left and right sides by a left and right vertical current line. In the middle is a circuit diagram made up of
contacts, coils, and connecting lines.

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Each network consists on the left side of a series of contacts which pass on from left to right the condition
"ON" or "OFF" which correspond to the Boolean values TRUE and FALSE. To each contact belongs a
Boolean variable. If this variable is TRUE, then the condition is passed from left to right along the
connecting line. Otherwise the right connection receives the value OFF.

INPUT represented by: | OUTPUT

represented by: 0

Addressing method:

1 slot=32 bit 2 word

(1 char./word=2 byte=16 bit)

Input addressing:

File letter: Slot number. Word number/Bit number

For example 1:2.1/1 Output

addressing:

File letter: Slot number. Word number/Bit number

For example 0:2.1/1

GENERALLY USED INSTRUCTIONS & SYMBOL FOR PLC PROGRAMMING:

Input Instruction:

1)-[]- This Instruction is Called XIC or Examine If Closed.

ie; If a NO switch is actuated then only this instruction will be true. If a NC switch is actuated then this
instruction will not be true and hence output will not be generated.

2)--[]-- This Instruction is Called XIO or Examine If Open

ie; If a NC switch is actuated then only this instruction will be true. If a NC switch is actuated then this
instruction will not be true and hence output will not be generated.

Output Instruction:

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1.--()-- This Instruction Shows the States of Output(called OTE). ie; If any instruction either XIO or XIC
is true then output will be high. Due to high output a 24 volt signal is generated from PLC processor.

2. (L) Output Latch (OTL)

OTL turns a bit on when the rung is executed, and this bit retains its state when the rung is not executed
or a power cycle occurs.

3. --(U)-- Output Unlatch(OTU)

OTU turns a bit off when the rung is executed, and this bit retains its state when the rung is not executed
or when power cycle occurs.

Rung:

Rung is a simple line on which instruction are placed and logics are created E.g.;

Timer:

Timer has three bit:

EN: Enable bit:

The Timer Enable (EN) bit is set immediately when the rung goes true. It stays set until the rung goes
false.

TT: Timer timing bit:

The Timer Timing (TT) bit is set when the rung goes true. It stays set until the rung goes

false or the Timer Done (DN) bit is set (i.e. when accumulated value equals preset value).

DN: Done bit:

The Timer Done (DN) bit is not set until the accumulated value is equal to the preset value. It stays set
until the rung goes false.

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Counter:

Counter has three bit:

Count Up bit (CU):

Set When Rung conditions are true and remains set till rung conditions go false or a RES instruction that
has the same address as the CTD instruction is enabled.

Done bit (DN):

Set when the accumulated value is => the present value and remains set till the accumulated value
becomes less than the present value.

Overflow (OV):

continues counting from there and remains set till a RES instruction that has same address as the CTD
instruction is executed or the count is incremented greater than or equal to +32,767 with a CTU
instruction.

Counter is two type:

1. CTU
2. CTD

CTU: Count Up

Increments the accumulated value at each false-to true transition and retains the accumulated value when
the instruction goes false or when power cycle occurs.

CTD: Count Down

Decrements the accumulate value at each false-to true transition and retains the accumulated value
when the instruction goes false or when power cycle occurs.

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Addressing of counter:

RESET: --(RES)--

Reset the accumulated value and status bits of a timer or counter.

C5:0

--(RES)-

When

A is true than counter C5:0 is reset.

BOOLEAN LOGIC DESIGN BY LADDER DIAGRAM:

1. AND logic

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2. OR logic:

3. NOT logic

4. NAND logic

5. NOR logic

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6. XOR logic

7. XNOR logic

PROGRAMING AND OPERATIONS IN PLC:

To understanding the programming and operation we consider an example. We have a car parking place
which has five car parking capacity and we want to control the parking gate/light. We have one input
sensor, one exit sensor, for power supply start stop push button, and for indication LED light

Making programme:

STEP: 1

Making start stop push button logic:

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Here button A is start push button and B is stop push button and X is binary type output.

STEP: 2

Making input side sensor logic:

Here we use one input sensor and one counter which is CTU (counter up) and take CTU preset value 5.

STEP: 3

Making exit side sensor logic:

Here we use one Exit sensor and one counter which is CTD (counter down) and take CTD preset value
5.

STEP: 4

Making parking light (LED) control logic:

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Here we take done bit (DN) of counter for controlling the LED light.

Operation:

After program making, it is download in plc. This program store in plc memory.

When we push the start button than plc scan the input means input condition of button A is true(1).so
the binary output is also true(1).

Binary output we can use as a input in next step, its status is true for sense the entering car we use a input
sensor and for counting the car we use a CTU because accumulator value less than preset value.

Similarly when fifth car enter than CTU count it's accumulator value.Now counter done bit is true
because CTU address is C5:0 and take its preset value 5 because parking place capacity is 5. When first
car enter then input sensor status goes true. Due to this CTU count one in its. accumulator value .but
counter done bit does not true accumulator value equal to preset value

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When done bit goes true than LED output is true so parking light is on.

At exit side, one car is goes outside form parking place. Now four car is present in the parking

place but CTU done bit is on so LED light is on. To remove this interlocking problem we use

same address for both counter (CTU and CTD).

Both counter have same address so CTU accumulator value and CTD accumulator value both are same.

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APPLICATIONS OF PLC:

1. The PLC can be programmed to function as an energy management system for boiler control for
maximum efficiency and safety.

2. In automation of blender recliners

3. In automation of bulk material handling system at ports.

4. In automation for a ship unloaded.

5. Automation for wagon loaders.

6. For blast furnace charging controls in steel plants.

7. In automation of brick molding press in refractory.

8. In automation for galvanizing unit.

9. For chemical plants process control automation.

10. In automation of a rock phosphate drying and grinding system.

11. Modernization of boiler and turbo generator set.

12. Process visualization for mining application.

13. Criteria display system for power station.

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SCADA

(SUPERVISORY CONTROL AND DATA ACQUISITION)

INTRODUCTION

SCADA stands for Supervisory Control and Data Acquisition. As the name indicates, it is not a full
control system, but rather focuses on the supervisory level. As such, it is a purely software package that
is positioned on top of hardware to which it is interfaced, in general via Programmable Logic Controllers
(PLCs), or other commercial hardware modules.

SCADA systems are used to monitor and control a plant or equipment in Industries such as
telecommunications, water and waste control, energy, oil and gas refining and transportation. These
systems encompass the transfer of data between a SCADA central host computer and a number of
Remote Terminal Units (RTUs) and/or Programmable Logic Controllers (PLCs), and the central host
and the operator terminals. A SCADA system gathers information (such as where a leak on a pipeline
has occurred), transfers the information back to a central site, then alerts the home station that a leak has
occurred, carrying out necessary analysis and control, such as determining if the leak is critical, and
displaying the information in a logical and organized fashion.

SCADA systems consist of:

1. One or more field data interface devices, usually RTUs, or PLCs, which interface to field sensing
devices and local control switchboxes and valve actuators

2. A communications system used to transfer data between field data interface devices and

control units and the computers in the SCADA central host. The system can be radio,

telephone, cable, satellite, etc., or any combination of these.

3. A central host computer server or servers (sometimes called a SCADA Center, master station, or
Master Terminal Unit (MTU)

4. A collection of standard and/or custom software [sometimes called Human Machine Interface (HMI)
software or Man Machine Interface (MMI) software] systems used to provide the SCADA central host
and operator terminal application, support the communications system, and monitor and control
remotely located field data interface devices.

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SCADA Software

1. Rockwell-RS view32
2. Siemens-winCC
3. Wonderware-Intouch
4. GE-Intellation

ARCHITECTURE:

Generally SCADA system is a centralized system which monitors and controls entire area. It is purely
software package that is positioned on top of hardware. A supervisory system gathers data on the process
and sends the commands control to the process. For example, in the thermal power plant the water flow
can be set to specific value or it can be changed according to the requirement. The SCADA system
allows operators to change the set point for the flow, and enable alarm conditions in case of loss of flow
and high temperature and the condition is displayed and recorded. The SCADA system monitors the
overall performance of the loop. The SCADA system is a centralized system to communicate with both

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wire and wireless technology to Clint devices. The SCADA system controls can run completely all kinds
of industrial process.

EX: If too much pressure in building up in a gas pipe line the SCADA system can automatically open
a release valve.

Hardware Architecture:

The generally SCADA system can be classified into two parts:

1. Clint layer
2. Data server layer

The Clint layer which caters for the man machine interaction. The data server layer which handles most
of the process data activities. The SCADA station refers to the servers and it is composed of a single PC.
The data servers communicate with devices in the field through process controllers like PLCs or RTUs.
The PLCs are connected to the data servers either directly or via networks or buses. The SCADA system
utilizes a WAN and LAN networks, the WAN and LAN consists of internet protocols used for
communication between the master station and devices. The physical equipment's like sensors connected
to the PLCs or RTUs. The RTUs convert the sensor signals to digital data and sends digital data to master
unit.

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Software Architecture:

Most of the servers are used for multitasking and real time database. The servers are responsible for data
gathering and handling. The SCADA system consists of a software program to provide trending,
diagnostic data, and manage information such as scheduled maintenance procedure, logistic information,
detailed schematics for a particular sensor or machine and expert system troubleshooting guides. This
means the operator can sea a schematic representation of the plant being controlled.

EX: alarm checking, calculations, logging and archiving; polling controllers on a set of parameter, those
are typically connected to the server.

Human machine interface:

The SCADA system uses human machine interface. The information is displayed and monitored to be
processed by the human. HMI provides the access of multiple control units which can be PLCs and
RTUs. The HMI provides the graphical presentation of the system. For example, it provides the graphical
picture of the pump connected to the tank. The user can see the flow of the water and pressure of the
water. The important part of the HMI is an alarm system which is activated according to the predefined
values.

For example: The tank water level alarm is set 60% and 70% values. If the water level reaches above
60% the alarm gives normal warning and if the water level reach above 70% the alarm gives critical
warning.

Monitoring/Control:

The SCADA system uses different switches to operate each device and displays the status at the control
area. Any part of the process can be turned ON/OFF from the control station using these switches.

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SCADA system is implemented to work automatically without human intervention but at critical
situations it is handled by man power.

DESIGN SCADA WITH INTOUCH WONDERWARE SOFTWARE AND APPLICATION:

SCADA is main interface between your control system and Operator. Maximum data and features
available on SCADA give you better control and clarity about the system. SCADA needs to read data
from various devices like:-

1. PLC/Controllers
2. RTU
3. Energy meters/Load managers/Data loggers
4. Field instruments like Flow meters and positioners

Each of above data communicates with SCADA on various protocols. SCADA reads or writes the data
in format of tags.

INTOUCH WONDERWARE SCADA SOFTWARE:

First we crate the animated object from "Wizard Selection" tool than specify tag name as require. We
can create almost any screen animation effect imaginable. We can make objects change colour, size,
location, visibility, fill level, and so on.

Animation link selection dialog box are shown in fig.

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A. User Input touch links:

Discrete: Used to control the value of a discrete tagname.

Analog: Used to input the value of an analog (integer or real) tagname..

String: Used to create an object into which a string message may be input.

B. Sliders touch links:

Vertical& Horizontal:

we can move the slider position horizontally or vertically.

C. Touch Pushbutton links:

Discrete Value:

Used to make any object or symbol into a pushbutton that controls the state of a discrete tagname.
Pushbutton actions can be set, reset, toggle, momentary on (direct) and momentary off (reverse) types.

Action:

Allows any object, symbol or button to have up to three different action scripts linked to it; On Down,
While Down and On Up.

Show Window:

Used to make an object or symbol into a button that opens one or more windows when it is clicked or
touched.

Hide Window:

Used to make an object or symbol into a button that closes one or more windows when it is clicked or
touched.

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LINKS:

Discrete:

Used to control the fill, line and text colours attributes of an object or symbol that is linked to the value
of a discrete expression.

Analog:

The line, fill, and text colour of an object or symbol can be linked to the value of an analog tag name
(integer or real) or an analog expression. Five value ranges are defined by specifying four breakpoints.
Five different colours can be selected which will be displayed as the value

range changes. The text, line, and fill colour of an object can all be linked to the alarm state of a tag
name,

Discrete Alarm:

Alarm Group, or Group Variable. This colour link allows a choice of two colours; one for the normal
state and one for the alarm state of the tag name. This link can be used for both analog and discrete tag
names. If it is used with an analog tag name, it responds to any alarm condition of the tag name.

Analog Alarm: The text, line, and fill colour of an object can all be linked to the alarm state of an analog
tag name, Alarm Group, or Group Variable. Allows a specific colour to be set for the normal state as
well as a separate colour for each alarm condition defined for the tag name.

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OBJECT SIZE LINKS:

We use Object Size links to vary the height and/or width of an object according to the value of an analog
(integer or real) tag name or analog expression. Size links provide the ability to control the direction in
which the object enlarges in height and/or width by setting the "anchor" for the link. Both height and
width links can be attached to the same object.

PERCENT FILL LINKS:

We use Percent Fill Links to provide the ability to vary the fill level of a filled shape (or a symbol
containing filled shapes) according to the value of an analog tag name or an expression that computes to
an analog value. For example, this link may be used to show the level of liquids in a vessel. An object
or symbol may have a horizontal fill link, a vertical fill link, or both.

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LOCATION LINKS:

We use Location Links to make an object automatically move horizontally, vertically, or in both
directions in response to changes in the value of an analog tag name or expression.

MISCELLANEOUS LINKS:

There are four type of miscellaneous links. Visibility:

Use to control the visibility of an object based on the value of a discrete tag name or expression.

Blink:

Used to make an object blink based on the value of a discrete tag name or expression.

Orientation:

Used to make an object rotate based on the value of a tag name or expression.

Disable:

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Used to disable the touch functionality of objects based on the value of a tag name or expression.

VALUE DISPLAY LINKS:

Value Display Links provide the ability to use a text object to display the value of a discrete, analog, or
string tag name. There are three types:

Discrete:

Uses the value of a discrete expression to display an On or Off user defined message in a text object.

Analog:

Displays the value of an analog expression in a text object.

String:

Displays the value of a string expression in a text object.

APPLICATIONS OF SCADA:

SCADA systems can be relatively simple, such as one that monitors environmental conditions of a small
office building, or incredibly complex, such as a system that monitors all the activity in a nuclear power
plant or the activity of a municipal water system. SCADA monitors and controls industrial,
infrastructure, or facility-based processes, as described below:

Infrastructure processes may be public or private, and include water treatment and distribution,
wastewater collection and treatment, oil and gas pipelines, electrical power transmission and
distribution, wind farms, civil defence siren 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.

Industries that are catered to are:

• Automotive
• Building Automation
• Cement & Glass
• Chemical
• Electronics
• Food and Beverage

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• Machinery & Manufacturing

• Aerospace & Defence
• Metals & Mining
• Oil & Gas
• Pharmaceutical
• Power, Utilities & Generation
• Transportation
• Water & Wastewater

ADVANTAGES:

The SCADA system provides on board mechanical and graphical information

The SCADA system is easily expandable. We can add set of control units and sensors according to the
requirement.

The SCADA system ability to operate critical situations.

Variable Frequency Drive (VFD)

A Variable Frequency Drive is used for applications wherein speed control is of an essential importance
due to load changes wherein the speed needs to be increased or decreased accordingly. Traditional
methods in existence have addressed this issue, each with their own drawbacks such as high motor
starting current, lower power factor, energy losses, etc. To address these problems, VFD provides a
flexible approach as compared to traditional methods of speed control especially for certain applications
which do not require a constant speed at all times. To name an example, a pump delivering cooling liquid
supply may require peak load operation only for a requisite period of time and may require only much
less amount during the remainder of the day. VFD will allow the speed of the pump to run at a lower
rate in such case thereby enabling energy saving benefits.

V/f method of speed control

The motor speed can be controlled by varying supply frequency. Voltage induced in stator is directly
proportional to product of supply frequency and air-gap flux. If stator drop is neglected, terminal voltage
can be considered proportional to product of frequency and flux. V1 a f. Effect of supply frequency
change without terminal voltage change:

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1. Reduction of supply frequency without change in terminal voltage will cause an increase in the
air gap flux thereby saturating the motor. This will cause the increase in magnetizing current,
core loss and stator copper loss and cause distortion in line current and voltage and produce high-
pitch noise.
2. Increase of supply frequency without change in terminal voltage will cause decrease in flux
therefore leading to reduction of torque capability of the motor.

The base speed of the induction motor is directly proportional to the supply frequency and the number
of poles of the motor. Since it is not possible to change the number of poles, the only option to change
the speed of the induction motor is by changing the supply frequency. The torque developed by the
induction motor is directly proportional to the ratio of the applied voltage and the frequency of supply.
By changing the voltage and the frequency, but by keeping their ratio constant, the torque developed can
be kept constant throughout the speed range. This is the main focus of V/f method of speed control.
Figure 3 shows the torque-speed characteristics of the induction motor with VF control A constant V/f
ratio produces a constant maximum torque, except at low speeds or frequencies. The maximum torque
will have lower value in motoring operation and larger value in braking operation due to reduction in
flux during motoring operation and increase in flux during braking operation. The advantages of this
method are:

1. Speed control of motor

2. Starting current required is lower.

3. Stable operating region of the motor is increased.

4. At base speed, the voltage and frequency achieve their rated values.
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5. Acceleration and deceleration of the motor can be controlled by controlling the change of supply
frequency to the motor with respect to time.

Overview of the proposed mechanism

A Variable Frequency Drive is a device used in a drive system consisting of the following three main
sub-systems: AC motor, main drive controller assembly, and drive operator interface. The AC electric
motor used in a VFD system is a three- phase induction motor which is generally the most economical
motor choice. The VFD controller is a solid state power electronics conversion system consisting of
three distinct sub-systems: a rectifier bridge converter, a direct current link, and an inverter. In a VSI
drive.

DC link consists of a capacitor which smoothens out the converter's DC output ripple and provides a
stiff input to the inverter. This filtered DC voltage is converted to quasisinusoidal AC voltage output
using the inverter's active switching elements. VSI drives provide higher power factor and lower
harmonic distortion than phase-controlled Current Source Inverter. VFD control has been chosen
specifically because they provide the advantages of energy savings, low motor starting current, reduction
of thermal and mechanical stresses on motors and belts during starts, simple installation, high power
factor and lower KVA. Variable Frequency Drives are generally required because many applications are
not run at the same speed all of the time due to surrounding circumstances. The revolutions per minute
of the driven shaft need to be increased or decreased depending on load changes, application requirement
or other circumstances. The PLC has been connected to control and monitor a VFD which is the acts as
a go between the three-phase induction motor and the PLC.

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Experimental setup

Rated Output

1. The Allen-Bradley PowerFlex 4M AC drive is the smallest and most cost effective drive which
provides powerful motor speed control in a compact, space saving design.

2. The PLC used in this project was Allen Bradley MicroLogix 1400 series. The basic parts of a
1400 series PLC are Power Supply, CPU, Discrete Input Module and Discrete Output Module.

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CONCLUSION:

With the speed of changing technology today it is easy to lose sight or knowledge of the basic theory or
operation of programmable logic. Most people simply use the hardware to produce the results they
desire. Hopefully, this report has given the reader a deeper insight into the inner workings of
programmable logic and its role in mechanical operations. The idea of programmable logic is very simple
to understand, but it is the complex programs that run in the ladder diagrams that make them difficult
for the common user to fully understand. Hopefully this has alleviated some of that confusion. SCADA
is used for the constructive working, using a SCADA system for control ensures a common framework
not only for the development of the specific applications but also for operating the detectors. Operators
experience the same "look and feel" whatever part of the experiment they control. However, this aspect
also depends to a significant extent on proper engineering.

An automation system is an integration of sensors, controls, and actuators designed to perform a function
with minimal or no human intervention. Adapting an automation system will produce substantial
benefits on profit, production rate, safety, and quality. Industrial automation technology helps businesses
enhance safety, save time, boost quality production, reduce monitoring, and lower costs. All of these
benefits lead companies to higher productivity, greater efficiency, and more profitability.

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Reference

1. ShapMyskills Pvt. Ltd

URL Portal: https://shapmyskills.in
2. Plant Automation Technology
URL Portal: https://www.plantautomation-technology.com/
3. Upkeep
URL Portal: https://www.upkeep.com/

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