Annexure-I

SUMMER TRAINING REPORT

on

PLC AND SCADA

Submitted by

Nerob Kumar Mohonto

Registration No:11800392
Programme Name:Electrical and Electronics Engineering

Under the Guidance of

Dr. Pradeep Kumar Mittal

School of Electronics & Electrical Engineering

Lovely Professional University, Phagwara

(June-July, 2019)
 Annexure-II

DECLARATION

I hereby declare that I have completed my six weeks summer training at Engineers Gurukul,Lovely
Professional University from 06-06-2019 to 20-07-2019 under the guidance of Dr.Pradeep Kumar
Mittal. I have declare that I have worked with full dedication during these six weeks of training and
my learning outcomes fulfill the requirements of raining for the award of degree of Bachelor of
Technology In Electrical and Electronics Engineering, Lovely Professional University, Phagwara.

(Signature of student)
Name of Student :Nerob Kumar Mohonto
Registration no:11800392
Date:27/07/2019
Table of Contents

DECLARATION II

1. Programmable Logic Controller

1.1 Introduction to PLC………………………………………………………………………………...2

1.2 History of PLC…………………………………………………………………………….……......2
1.3 Component of PLC……………………………………………………………………………........2
1.4 Feature of PLC…………………………………………………………………………......……….3
1.5 Use of PLC………………………………………………………………………………......…….3
1.6 Advantages and Disadvantages…………………………………………………………….......…...3

2. Operation of PLC

2.1 Block diagram of PLC………………………………………………………………………...……4

2.2 PLC operation....................................................................................................................................5
2.3 PLC scan cycle................................................................................................................................6
2.4 Ladder logic.......................................................................................................................................6
2.5 Ladder Logic Programming.............................................................................................................10
2.6 Counters & Timers..........................................................................................................................................................................11
2.7 PLC application example................................................................................................................13

3. Programming of PLC

3.1 Logic gate operation.........................................................................................................................14

3.2 Light control.....................................................................................................................................19
3.3 Heater temperature control.............................................................................................................22
3.4 Single phase motor control.............................................................................................................23

4. Supervisory Control And Data Acquisition(SCADA)

4.1 Introduction to SCADA...................................................................................................................24

4.2 Architechture of SCADA..................................................................................................................24
4.3 Application ofSCADA .....................................................................................................................25

5.Project (Software Development)

5.1 PLC Program to Control Level of a Single Tank..............................................................................26

5.2. Graphical figure................................................................................................................................26
5.3 problem solution...............................................................................................................................27
5.4 Ladder program ...............................................................................................................................28
5.5 Program Description ........................................................................................................................29

6. Conclusion ..........................................................................................................................................30

References ...............................................................................................................................................31

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1. Programmable Logic Controller

1.1Introduction to PLC

PLC stands for Programmable Logic Controllers. They are basically used to control automated systems
in industries. They are one of the most advanced and simplest forms of control systems which are now
replacing hard wired logic relays at a large scale
.
Programmable Logic Controllers (PLCs) are small industrial computers with modular components
designed to automate customized control processes. PLCs are often used in factories and industrial
plants to control motors, pumps, lights, fans, circuit breakers and other machinery.

1.2.History of PLC

Programmable logic controllers (PLCs) first hit the scene in the late 1960s. 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.

Some companies proposed schemes based on the Digital Equipment Corp. DEC PDP-8, the widely-
used mini-computer at the time. Dick Morley’s company Bedford Associates in Massachusetts
proposed something called a Modular Digital Controller (MODICON). The MODICON 084 brought
the world’s first PLC into commercial production.

Since then, a slow steady growth has allowed the manufacturing and process control industries to take
advantage of PLC applications-oriented software—programmable language that looks and feels like
relay-ladder-logic where any maintenance technician.

Morley is generally credited with the “invention” of the PLC. However, there were many others
involved in the birth of this landmark development, including the late Odo Struger (from Allen-
Bradley, now Rockwell).

Morley said details of the PLC came about on 1 January 1968. Some 35 years later, it is arguably the
most widely used product in the industrial automation business, with a worldwide market of several
billions of dollars per year. PLC products are available from hundreds of different sources, in many
different form-factors (including embedded controllers), and with prices ranging from tens of
thousands of dollars (for triple redundant, failure-proof systems) to commodity products at less than a
hundred bucks.

1.3 Component of PLC

The following components are commonly used in PLC :

1.processor or central processing unit (CPU);

2.rack or mounting;
3.input assembly;
4.output assembly;
5.power supply;
6.programming unit, device, or PC/software
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1.4 Feature of PLC

PLC control system is that it regards PLC as control key component, utilize special I/O module to form
hardware of control system with a small amount of measurement and peripheral circuit, to realize
control to the whole system through programming.

1. High Reliability: Strong anti-interference quality and very high reliability are the most important
features of PLC. In order to make PLC work stably in strong interferential circumstance. Many
techniques are applied in PLC. Software control instead of relay control mode can decrease faults
which are brought about by original electric contact spot outside working badly. Industrial grade
components made by advance processing technology can resist interferences, and self diagnosis
measures of watchdog circuit for protecting memory can improve performance of PLC greatly.

2. Good Flexibility : There are several programming languages for PLC including ladder diagram,
SFC, STL, ST and so on. If operator can master only one of programming languages, he can operate
PLC well. Every who want to use PLC has a good choice. Based on engineering practice, capacity and
function can be expanded by expanding number of module, so PLC has a good flexibility.

3. Quality of Strong Easy-Operating: It is very easy to edit and modify program for PLC by computer
offline or online. It is very easy to find out where the fault lie by displaying the information of fault and
function of Self Diagnosing Function, and all these make maintenance and repair for PLC easier. It is
very easy to configure PLC because of modularization, standardization, serialization of PLC.

4. Smaller and Faster : Modern PLC is smaller in size .We need a little place for it.As it smaller in size
but it gives faster better performance .

1.5 Use of PLC

PLC widely used in following sector :

1. Wind turbine operation

2. The smart factory
3. Glass production
4. Cement manufacturing
5.Virtual modelling

1.6 Advantages and Disadvantages

Advantages of PLC :

1.Very fast
2.Easy to change logic i.e. flexibility
3.Reliable due to absence of moving parts
4.Low power consumption
5.Easy maintenance due to modular assembly
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6.Facilities in fault finding and diagnostic
7.Capable of handling of very complicated logic operations
8.Good documentation facilities
9.Easy to couple with the process computers
10.Analog signal handling and close loop control programming
11.Counter, timer and comparator can be programmed
12Ease operator interface due to colourographic and advisory system introduction

Disadvantages of PLC :

1. There's too much work required in connecting wires.

2. There's difficulty with changes or replacements.
3. It's always difficult to find errors; And require skillful work force.
4. When a problem occurs, hold-up time is indefinite, usually long.
5.skilled technician required to operate PLC

2.Operation of PLC

2.1Block diagram of PLC:

Fig.2.1 .1 Block diagram of PLC

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Brief description of block diagram :

1) I/O Section:-

The I/O section establish the interfacing between physical devices in the real world outside the PLC
and the digital arena inside the PLC.

The tasks of the I/O section can be classified as:

1.Conditioning
2.Isolation
3.Termination
4.Indication

2) CPU Section:-

The Central Processing Unit, the brain of the system is the control portion of the PLC. It has three
Subparts.
1.Memory System
2.Processor
3.Power Supply

3) Programmer/Monitor:-

The Programmer/Monitor (PM) is a device used to communicate with the circuits of the PLC.The
programming unit allows the engineer/technicians to enter the edit the program to be executed.

2.2PLC operation:

The operation of a PLC is very simple. The processor makes decisions based on a ladder logic program
written by the user. In order to use the program properly, the PLC must communicate with the various
field devices it is tasked with monitoring and controlling. It then compares the actual conditions of the
field devices with what the program instructs them to do, and updates the output devices accordingly.

Operational Sequence

The operational sequence is as follows:

1.Input switch is pressed.

2.Input module places a “1″ in the input data table,
3.The ladder logic program sees the “1″ and caused a “1″ to be put into the output data table.
4.The output data table causes the output module to energize associated point.
5.The output device energizes

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2.3 PLC scan cycle:

Fig. 2.3.1 Scan cycle of PLC

PLCs operate by continually scanning programs and repeat this process many times per second.
When a PLC starts, it runs checks on the hardware and software for faults, also called a self-test. If
there are no problems, then the PLC will start the scan cycle. The scan cycle consists of three steps:
input scan, executing program(s), and output scan
.

Input Scan: A simple way of looking at this is the PLC takes a snapshot of the inputs and solves the
logic. The PLC looks at each input card to determine if it is ON or OFF and saves this information in a
data table for use in the next step. This makes the process faster and avoids cases where an input
changes from the start to the end of the program.

Execute Program (or Logic Execution): The PLC executes a program one instruction at a time
using only the memory copy of the inputs the ladder logic program. For example, the program has the
first input as ON. Since the PLC knows which inputs are ON/OFF from the previous step, it will be
able to decide whether the first output should be turned ON.

Output Scan: When the ladder scan completes, the outputs are updated using the temporary values in
memory. The PLC updates the status of the outputs based on which inputs were ON during the first step
and the results of executing a program during the second step. The PLC now restarts the process by
starting a self-check for faults.

2.4 Ladder logic

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Ladder diagram, better known as ladder logic, is a programming language used to program PLCs
(programmable logic controllers). This article will briefly describe what ladder logic is and go over
some examples of how it functions.

Programmable logic controllers or PLCs are digital computers used to perform control functions,
usually for industrial applications. Of the various languages one can use to program a PLC, ladder logic
is the only one directly modeled after electromechanical relay systems.

It uses long rungs laid out between two vertical bars representing system power. Along the rungs are
contacts and coils, modeled after the contacts and coils found on mechanical relays. The contacts act as
inputs and often represent switches or push-buttons; the coils behave as outputs such as a light or a
motor.

Outputs don't have to be physical, though, and can represent a single bit in the PLC's memory. This bit
can then be used later on in the code as another input. Contacts are placed in series to represent AND
logic and in parallel when using OR logic. As with real relays, there are normally open contacts and
normally closed contacts.

An Example of Ladder Logic:

Fig. 2.4.1 Example of ladder logic

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This ladder logic program is three rungs long. The program is “scanned” or run by the CPU from left to
right and top to bottom. The symbols placed throughout the rungs are actually graphical instructions.
The names for these instructions are:

1.XIC (Examine If Closed)

2.XIO (Examine If Open)
3.OTE (Output Energize)

First Rung:

Looking at the first rung, notice the first two inputs I:1/1 and I:1/2. The symbol is an XIC, and the I
denotes that this is an input. This instruction represents a physical input found on one of the discrete
input cards.

Fig. 2.4 .2First rung

Second Rung

On the second rung, we have a third input labeled I:1/3 and our internal bit is now used with an input
instruction instead of an output

8
 Fig 2.4.3Second rung

Third Rung

The third rung introduces the XIO instruction. An XIO instruction is best described as true if open.

9
 Fig.2.4.4 Third rung

2.5 Ladder Logic Programming

Ladder Logic Programming Introduction Ladder logic are 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 diagrams that plant electricians al- ready knew. A program
in ladder logic, also called a ladder diagram, is similar to a schematic for a set of relay circuits. Ladder
logic is widely used to program  where sequential control of a process or manufacturing operation
is required.

Fig. 2.5.1 Basic ladder logic program

Ladder logic is useful for simple but critical control systems, or for reworking old hardwired relay
circuits. As programmable logic controllers be- came more sophisticated it Ins also been used in very
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complex automation systems .A simplified ladder logic circuit with one input and one output. The logic
of the rung above is such:

Fig. 2.5.2 Basic program to show input and output

1.If Input l is ON (or true) - power (logic) completes the circuit from the left rail to the tight rail - and
Output l turns ON (or true).

1. If Input l is OFF (or false) - then the circuit is not completed and logic does not flow to the right
- and Output 1 is OFF (or false).

With just a handful of bas sic symbols such as a normally open contact, normally closed contact,
normally open coil, normally closed coil, timer and counter most logical conditions can be
represented.

2.6 Counters & Timers

PLC timers are instructions that provide the same functions as on-delay and off-delay mechanical and
electronic timing relays. A PLC timer provides a preset delay to the control actions.

In general, there are three types of PLC timer delays, ON-delay timer, OFF-delay timer and retentive
timer on.

The terms represented in the timer block in the PLC are a Preset value which means the delay period of
the timer, an Accumulated value which is the current delay of the timer.

A timer begins the counting on time-based intervals and continues until the accumulated value equals
the preset value. When the accumulated value equals the preset time the output will be energized. Then
the timer sets the output.

TON timer or ON delay timer

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An ON delay timer is used where we need a time delay before the time delay before an instruction
becomes true .

Fig.2.6.1ON delay timer

.

A representation TON timer is shown above, which contains,

Timer number: The timer file name

Time base: which is shown in seconds,
Preset value: Numeric valve set as the delay required to the timer.
Accumalated value: The values are counting is displayed from zero. Value becomes zero whenever the
timer is reset

TOFF timer or OFF delay timer:

A TOFF timer will keep the output energized for a preset time after the rung signal has gone false.

Fig.2.6.2 OFF delay timer

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Retentive timer:

A retentive timer is used when you want to retain accumulated time value through the power loss or the
change in the rung state.

A retentive timer accumulates time whenever the device receives power, and it maintains the current
time should power be removed from the device.

2.7 PLC application example

1. A signal lamp is required to be switched on if a pump is running and the pressure is satisfactory,
or if the lamp test switch is closed.

For the inputs from the pump and the pressure sensors we have an AND logic situation since both are
required if there is to be an output from the lamp. We, however, have an OR logic situation with the test
switch in that it is required to give an output of lamp on regardless of whether there is a signal from the
AND system.

2.As another example, consider a valve which is to be operated to lift a load when a pump is running
and either the lift switch is operated or a switch operated indicating that the load has not already been
lifted and is at the bottom of its lilt channel.

3. As another example, consider a system where there has to be no output when any one of four
sensors gives an output, otherwise there is to be an output.

One way we could write a program for this is for each sensor to have contacts that are normally closed
so there is an output.

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3. Programming of PLC

3.1 Logic gate operation

1.OR gate: In OR gate if any one input is high then output will be high and if both the inputs ae low
then output will be low .
OR operation is represented by C = A + B

Fig 3.1.1 OR gate Fig 3.1.2 OR agte truth table

2.NOT gate : In NOT gate if input is low then putput is high and if input is high then putput is low .

NOT operation is represented by C=A

Fig 3.1.3 NOT gate Fig 3.1.4 NOT gate truth table

3.AND gate: IN AND gate if both of the inputs are high then output will be high othwewuse output
will be low .
AND operation is represented by C = A • B

Fig 3.1.5 AND gate Fig 3.1.6 AND gate truth table

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4.NAND gate : In NAND gate if both of the input is high then it gives low output otherwise it gives
high output.
NAND gate is represented by C = A .B

Fig 3.1.7 NAND gate

Fig.NAND gate truth table

5.NOR gate : NOR gate is the combination of NOT gate and OR gate .In NOR gate if both of the input
is low then output is high othrewise it gives low output.

Fig.3.1.8 NOR gate

Fig.3.1.9 NOR gate truth table

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6.XOR gate: IN XOR gate if any one input is high then output is high and if both of the inputs are high
or low then it gives low output.

Fig.3.1.10 XOR gate

Fig.3.1.11 XOR gate rtuth table

7.XNOR gate : In XNOR gate if both of the input is same then it gives high output.

Fig.3.1.12 XNOR gate diagram and truth table

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Attachment: Screenshoots are attached

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18
3.2 Light control: when any one switch preseed nothing happened .when any two switch are preseed
red light become on and when three switch are pressed yellow light become on and when four switch
are pressed green light become on.

Attachment: Screenshoots are attached.

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20
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3.3 Heater temperature control: when temp is 10 degree all three heaters are on ,when temp is 20
degree two heaters are on ,when temp is 30 degree then only one heatre is on and when temp is 40
degree then no heater will on.
10 degree by 1/0
20 degree by 1/1
30 degree by 1/3

Attachment:Screenshoors are attached.

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3.4 Single phase motor control: Forward reverse circuit
used where motor used in both clockwise and anti-clockwise direction .This system is usually
used for indusrtrial purpose.

Attachedment: Scrennshoots are attached.

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4. Supervisory Control And Data Acquisition(SCADA)

4.1 Introduction to SCADA: SCADA is Supervisory Control And Data Acquisition is a software
application program for process control, which refers to do both Data acquisition and Communication
interface.
SCADA is a central control system which consists of controller network interfaces, input or output
communication equipment and software. SCADA system control and monitor the industrial process.

SCADA is combination of telemetry and data acquisition

4.2 Architechture of SCADA:

Basic components of SCADA system are:

1.Field instrumentation
2.Remote station (RTU)
3.Communication network
4.Master station (MTU)
5.Commercial Data processing computer (client)

Fig.4.1.1 Basic Architechture of SCADA

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4.3 Application of SCADA

Here are a few of the most common uses for SCADA systems:
1.Manufacturing
2.Food Production
3.Electric and gas utilities
4.Waste water treatment
5.Telecom and information technology(IT)

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5.Project (Software Development)

5.1 PLC Program to Control Level of a Single Tank: The problem is, One tank is installed in a
plant which is to be controlled .When water lavel reaches the Low level the outlet flow must be
blocked and inlet water flow is allowed untill High level is achived.When High level is detected the
outlet flow must be allowed and inlet flow is blocked.

5.2. Graphical figure

Fig.5.2.1 Graphical figure of water level control

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5.3Problem Solution

1.To detect high and low level of liquid in the tank, two level switches are used which gives output in
digital terms, that is when corresponding levels are detected, it gives output high otherwise remain low.

2.To control level of this system, Single Acting piston valve can be used which has two states, either
fully open or fully close.

3Low Level Switch is mounted at the bottom of the tank and Level High switch mounted at the side
upper most position.

4.When this inputs are detected, output to Control Valve has to be latched in order to continuously fill
or empty the system.

5.Master start/stop is also provided to shut down or start the entire process.

PLC Program:

Here is PLC program to Control Level of a Single Tank, along with program explanation and run time
test cases.
List of Inputs and Outputs

I:1/0 = Level High Switch (Input)

I:1/1 = Level Low Switch (Input)
O:2/0 = Inlet Valve (Output)
O:2/1 = Outlet Valve (Output)
I:1/14 = Start (Input)
I:1/15 = Stop (Input)

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5.4 Ladder program :

Fig.5.4.1 Ladder program of water level control

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5.5 Program Description

1. RUNG000 is simply hold a coil and master start-stop buttons.

2.RUNG001 is to control the outlet valve through O:2/1. This is done when Level High is detected.

3.Latching of Output O:2/1 is done because when High Level is detected, input to RUNG001 is
temporary, like Push Button. So in order to keep outlet valve open until the Level Low I:1/1 is detected,
latching is done. XIO of Level Low Switch is connected in series so that when Level Low is detected,
it goes true closing the outlet valve.

4.Similarly in RUNG002, it works exactly same. The only difference in RUNG002 is that extra I:1/14
contact in parallel with LLS.

5.Suppose when the system is started and the tank is partially filled, neither LHS nor LLS is detected,
in this case, outlet and inlet valves remain closed while inlet valve should open to start filling the tank
because it’s partially filled.

6.To eliminate this error, I:1/14 (Start) is connected in parallel to LLS I:1/1 contact. This checks if LHS
(I:1/0) is detected or not. If LHS is not detected, then it opens the inlet valve until LHS is detected.

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6. Conclusion: Programmable logic controller (PLC) language has helped to develop the control
system and it has become the most useful language. Programmable Logic Controllers have become the
language that most companies and factories use. They supply and support engineers with what they
need and they keep operators protected from hazardous machines. The potential of programmable logic
controllers in controlling systems is almost limitless. Programmable logic controls have fed and
supported control systems in many ways. Most process computers utilized in factories with humans
have more advantages than disadvantages as a secure system when dealing with complex process.
Programmable logic controllers have proven to be an effective and helpful tool in many industries in
the past. With their many advantages, they will continue to be useful in the future as well.

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REFERENCES

1. https://www.ukessays.com/essays/computer-science/programmable-logic-controller-system-plc-
computer-science-essay.php
2. https://electrical-engineering-portal.com/download-center/books-and-guides/siemens-basics-of-
energy/basics-of-plcs
3. https://www.sanfoundry.com/plc-program-control-level-single-tank/
4. https://automationforum.in/t/basics-of-scada-system-and-its-application/2817

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