Industrial Automation

Transcription

1 Software Development & Education Center Industrial Automation (PLC SCADA)

2 Industrial Automation Automation is the use of machines, control systems and information technologies to optimize productivity in the production of goods and delivery of services. The correct incentive for applying automation is to increase productivity, and/or quality beyond that possible with current human labor levels so as to realize economies of scale, and/or realize predictable quality levels. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provides human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements while increasing load capacity, speed, and repeatability. Automation plays an increasingly important role in the world economy and in daily experience. Audience Profile This course is especially for persons coming from the colleges or industry who need to have the right knowledge of PLC applications, instructions, programming, troubleshooting & interfacing. Allen Bradely and Siemens PLCs are covered. As SCADA is also an integral part of automation; they are also included in the syllabus. Real Life Case Studies and Application Examples will be taken to make the short course truly beneficial. The sharing of experience and ideas amongst participants helps in increasing the knowledge of individuals. Opportunities after the Course Nowadays energy efficiency in industrial processes is becoming more and more relevant. Semiconductor companies like Infineon Technologies are offering 8-bit micro-controller applications for example found in motor controls, general purpose pumps, fans, and e-bikes to reduce energy consumption and thus increase efficiency. One of Infineon`s 8-bit product line found in industrial automation is the XC800 family. Now that we re moving towards automated orange-sorting and autonomous tractors, the next step in automated agriculture is robotic strawberry pickers. In short Industrial Automation Creates a huge opportunity in the various domains like Manufacturing, Production, Electrical, Agriculture, Power, Energy, Chemical, Petroleum & Gas, Research & Development and many other industries.

3 Detailed Curriculum MODULE 1: PLC (Programmable Logic Control) Introduction to Automation Brief Description of a Control System. Micro Controller, PID Controller, PLC Controller. History & Need of Industrial Automation. Application of Industrial Automation. Basic Components of Automation. Hardware Classification of Automation. PLC Details History of PLC Difference between relay, contactor & PLC logic PLC architecture A detailed description of different PLC modules & cards Introduction to PLC Application and Advantage of PLCs. Architecture of a PLC. Source and Sink type of PLC. Programming Language of a PLC. Hardware over View of Mitsubishi series of PLC. Controls Wiring of PLC. Data files used in a PLC. Interfacing with Relay. Control circuit designing with feedback concept. Interfacing proximity sensor with PLC. Communication with PC. Wiring different field device to PLC. Simulator analysis of a PLC Programming. Uploading, Downloading & Monitoring programs. Introduction to SFD, Instruction List and Ladder Logic. Monitoring/Modifying Data table values. Hands on experience on real time applications. Fault finding/troubleshooting and documentation.

4 I/O configuration & Memory Mapping Why I/O configuration is required? How the I/O modules are addressed for AB & Siemens PLCs Programs & Ladder Diagrams First steps with the programming device Introducing the basic ladder logic Instructions, contacts, coils, and PLC scan. The Instruction Set A look at the instructions covered in all PLCs. Each instruction being illustrated by application specific program examples The instructions covered are:- NO/NC, Set, Reset, Timers, Counters, Comparison, Arithmetic, Logical & Move functions Communications & fault finding An introduction to communication options available for the type of PLCs Ladder Logic Programming Comparison b/w Gate, Relay ladder & PLC logic. Description of using Memory bit in a programming. Mathematical Concept ADD, SUB, MUL, DIV and etc. Logical Concept AND, ANI, OR, ORI, EXOR, NOT etc. Special Function MOV, SET, RST, CMP, INC, DEC. Programming based on Timer and Counter. Advance Control function programming. MODULE 2: SCADA COMMUNICATION Introduction Introduction to SCADA Software. Creating new SCADA Project. GUI Designing. Tag Substitutions. Dynamic Process Graphic. Real Time and Historical Trend. Alarms & Event.

5 Recipe Management. Attaching controls to graphic object, Sizing, Blinking, Filling, Analog Entry, Movement of Objects and Visibility. SCADA and Networking. Communication with PLC. Interfacing SCADA via Excel, via PLC, via Relay, via Motor/LED. Fault finding/troubleshooting. Application Development Creating a new SCADA application Creating Database of Tags Creating & Editing graphic display with animation Data Entry / Start Stop command Analog entry Sizing Blinking Movement Visibility Filling Trending Creating & Accessing Real-time Trends Creating & Accessing Historical Trends Creating Alarms & Events Writing logic through script Application script Data Change Special functions Connectivity with the different hardware Condition Window script Communication protocols Communication with PLC Communication with Data Acquisition System Connectivity between software Communication with Excel Communication with Visual Basic Commissioning the network nodes Troubleshooting the application

6 AC Drives Fundamentals of AC Drive Block diagram of AC drive Configuration of different drives Control of drive with and without PLC Various applications of AC Drive Interfacing with PLC MODULE 3: RELAY & SENSOR INTERFACING RELAY LOGIC Basic principle of Relay working. Making AND, OR gate, NOT gate logic circuit. Interfacing relay with sensor. Relay based Control designing. Interconnection between Different Relay & Switch`s. Contactor Working DOL Starter. Forward And Reverse DOL. Star Delta Starter (including timer). Interlocking Circuit. Inching process. Contactor Based control Diagram. Timer Interfacing Basic Principle of Industrial Timer. Delay generation. Wiring connection of timer to the different device. Controlling switching between different devices. Interfacing with relay and contactor. Alarm generation. SENSOR AND PROCESS INSTRUMENTATION Introduction to various Sensors/Instrumentation used in Industry. Temperature measurement (Thermocouple, RTD, thermistor). Working on the proximity sensor.

7 Introduction to limit switch. Working on the photo electric sensor. Temperature controller. Level sensor. Flow measurement and its working principle. Pressure measurement and its working principle. LVDT Displacement Sensor. Load and level measurement. Solenoid valve working and it`s Principle. Making Switches by using Sensor.

8 Industry Interface Program Projects Assignments / Mini Projects 1 Major Project Domains / Industry Electricals and Electronics Telecom & Communication Automobile Consumer Electronics Power & Energy Manufacturing Architecture Civil Industry Research & Development Automation Industry Retail Industry Health Care Industry Petroleum & Gas Research & Development Product Development Thermal & Electrical

9 Training & Performance Tracking Knowledge related to current technology aspects and corporate level deliverable & Continuous training and assessment to make you industry ready. Throughout the Training Curriculum Candidate will go through a Scheduled Assessment Process as below: Continues Assessments Practical Workshops Modular Assignments Case Studies & Analysis Presentations (Latest Trends & Technologies) Tech Seminars Technical Viva Observing live Models of various projects Domain Specific Industry Projects Project Work: Bottling Plant Automation System Designing & Simulation Metro Rail Automation System Designing & Simulation Power Generation Systems For Coal Industry Power Generation Systems For Uranium Industry HVAC System Design & Simulation Data Acquisition and Simulation with LabVIEW WSN (Wireless Sensor Network) for Telecom Industry WSN for Industrial Networking Power Distribution System Designing & Simulation EPC (Erection Procurement & Commissioning) System Design for Water Treatment Plants EPC (Erection Procurement & Commissioning) System Design for Oil & Natural Gas Plants Control Panel Designing with AutoCAD

10 Skills Development Workshop Communication is something which all of us do from the very first day of our life, yet there is a question that haunts us most of the time Did I express myself correctly in such and such situation? The answer to this question is really tricky, because in some cases we leave our signatures and good impression but in some others we even fail to get our idea clearly. It happens mostly because we don t know how to act in certain situations. Every time we fail we don t lose completely, we do learn something, but prior knowledge of the same thing could be more beneficial because then we could have turned that failure into success. The course / workshop would focus at many aspects of personality, like: Building positive relationships with peers & seniors Building self-confidence & Developing clear communication skills Exploring and working on factors that help or hinder effective interpersonal communication Learning impacts of non-verbal behavior & Dealing with difficult situations and difficult people Workshops Consists of Following Activities: Personality Development Group Discussions & Debates Seminar & Presentations Case Studies & Analysis Corporate Communication HR & Interview Skills Management Games & Simulations Aptitude, Logical & Reasoning Assessments & Development Action Based Learning