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VEPA INTEC

TRAINING COURSE

PLC/DCS/SCADA
SYSTEM ENGG
AND
PROGRAMMING
MODULE C
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
ABOUT VEPA INTEC.

Controlsoft
Engineering is in
Our Training
the field of
facility equipped Our main objective
Industrial VEPA INTEC
with modern tools, is to develop the
Automation and Training facility is
software and professional
Group company of detailed located in the
engineering lab for competence of the
Controlsoft engineering for the heart of Chennai,
training the aspirant through
Engineering. past 14 years and well connected
aspirants on all sharing of our
had executed with public
practical aspects knowledge and
many domestic transport.
of Instrumentation experience.
and overseas
and automation.
projects
successfully.
EXCELLENCE IN INSTRUMENTATION ENGINEERING AND AUTOMATIOIN TRAINING

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Course Sessions
Session No Course Contents

Session 1 Industrial Instrumentation Basics

Session 2 Electrical Symbols and relay Logic

Session 3 Instrumentation & Control System

Session 4 What is a PLC or a DCS and its system Architecture

Session 5 Programming a PLC using IEC Programming Language

Session 6 Ladder Logic Programming

Session 7 Exercises On Ladder Logic Programming using Rockwell and


Siemens PLC
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Course Sessions
Session No Course Contents

Session 8 Exercises On Ladder Logic Programming using Rockwell and


Siemens PLC
Session 9 Function Block and Sequential Function Chart Programming

Session 10 PLC Programming Exercise using Function Block & SFC using
Rockwell and Siemens PLC

Session 11 What is SCADA and PLC/SCADA vs DCS and how to configure a


SCADA?
Session 12 SCADA Screen Development and database development
Exercises
Using PcVue, Rockwell and Siemens SCADA software
Session 13 SCADA Screen Development and database development
Exercises, Using PcVue, Rockwell and Siemens SCADA software
Session 14 SCADA and PLC integration
VEPA INTEC
and testing exercises MODULE C
PLC/SCADA System Engineering and Programming
Course Sessions
Session No Course Contents

Session 15 SCADA and PLC integration and testing exercises

Session 16 PLC/SCADA Project Planning, FDS and FTS preparations

Session 17 Control Panel Design and Wiring Schematics

Session 18 Panel Mounted HMI and its configuration and screen development

Session 19 Exercises on HMI configuration & Screen Development using


Rockwell/Siemens HMI

Session 20 Exercises on HMI configuration & Screen Development using


Rockwell/Siemens HMI
Session 21 PLC Selection, Installation, commissioning and troubleshooting
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Course Sessions
Session No Course Contents
Demo Project Design and engineering of a demo PLC project System
Engineering, preparing FDS, Programming of PLC, configuration
of SCADA, Integrating and testing PLC with SCADA 50 Hours
Real time on going Deputation to Controlsoft Engineering to carry out part of an
Projects ongoing PLC programming project 50 hours

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 1 - Industrial Instrumentation - Basics

What is a plant/industry?

Types of Manufacturing and example of manufacturing industries

What is a chemical process and what are different types of it?

What do measurement and Instrumentation mean?

What are different type of Measurement/Instruments?

What are different type of measurement/instrument function?

Instrumentation Signal Levels

What does Process Control Mean?

Process Control Implementation

Complete Plant Control Solution


PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 2 Electrical Symbols and Relay Logics

Electrical Symbols
What is an Interlock?
What is a sequence control?
How to understand an electrical wiring and interlock
diagrams using relay logics
Exercises on preparing electrical interlock diagrams using
relay logics
Motor Start/stop Circuit diagrams with interlocks
Level Controls
Exercises on preparing electrical sequence control using
relay logics
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 3 Instrumentation and Control System

Measurement & Instrumentation


Analog and Digital Devices
Instrumentation Signal Levels
Process Control PID, Cascade, Ratio
Control Loops
Automatic and Manual Controls
Instrumentation Interface to PLC/DCS
Controllers
Piping and Instrumentation Diagrams and
Instrument symbols and representation
Preparation of IO list from P and I Ds
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 4 What is PLC and its System Architecture

PLC & ITS HISTORY


PLC HARDWARE
PLC OPERATION
PLC COMMUNICATION
RS 232 & RS 485 communication
ISO/OSI MODEL AND PROTOCOLS
SINKING/SOURCING OF IOS
PLC INPUT/OUTPUT UNITS
PLC ANALOG INPUT/OUTPUT MODULES
CHOOSING THE CORRECT IO MODULES
PLC NETWORKS
PLC/DCS Manufacturers and PLC Models
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 5 Programming a PLC
Standard Programming using IEC
61131-3 language guidelines
Ladder Logic (LD)
Function Block Diagram (FBD)
Structured Text (ST)
Instruction List (IL)
Sequential Function Chart (SFC)
Continuous Function Chart(CFC)
PLC Instructions
Explanation & Examples of
programming using the above
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 6 Ladder Logic Programming
Ladder Logic Symbols
Ladder Logic Execution and
Programming
Ladder Logic programming
example using Rockwell and
Siemens programming Software
Motor Start/Stop
Traffic Signal
Level Control

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 7 Exercise 1 on Ladder Logic Programming
Using Rockwell or Siemens PLC create a ladder logic program
for the process scheme shown in the P and I D
The reactor batch shall be started through a START push button
The charging of raw material can happen only when the Reactor is
empty and the bottom valve is closed
When the Raw materials cumulative flow reaches the set point the
inlet valves shall get closed
The agitator should run only when the level in the reactor is > 20%
The reactor should take place for hour after charging the raw
materials and an alarm to be generated at the end of hour that the
reaction is over
The pump shall be started only when the receiver vessel level is less
than 20% and it should stop when the level in the reactor reaches 0%.
Once the reactor is empty an alarm to be generated stating the
reactor is over and the reactor is ready for next batch.
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 8 Exercise 2 on Ladder Logic Programming

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 9 Function Block (FBD) and Sequence Function
Chart(SFC) programming
Boolean Equations and Truth Tables
Logic Functions
Memory Functions (Latching)
Timing Functions
Counting Functions
Function Block Diagram Examples
Advanced Function Blocks
SFC programming Concepts
Steps and Transitions
Actions
Convergent/Divergent Transitions
SFC programming examples
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 10 PLC programming exercises using FBD and
SFC

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 11 What is SCADA & SCADA vs DCS
SCADA Definitions
SCADA Functions
SCADA Features presentation
SCADA Communication to PLCs
Open Communication-Modbus
Serial and Modbus TCP
OPC and DDE Communication
Web Server and Mobility SCADA
SCADA vs DCS
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 12 SCADA Screen Development and Database
Building Exercises

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 13 SCADA Screen Development and Database
Building Exercises

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 14 SCADA and PLC integration and Testing
Exercises

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 15 SCADA and PLC integration and Testing
Exercises

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 16 PLC/SCADA project planning and Design
Development
Understand Customer Requirement
Reading of P and I D /Block Diagram
Preparation of IO list
Preparation of Functional Design Specifications
(FDS)
Preparation of functional analysis/Flow chart for
programming
Preparation of Graphic Design basis
Preparation of Functional Test Specifications
(FTS)
Internal Integrated Testing (IIT)
Factory Acceptance Testing (FAT)
Site Acceptance Testing (SAT)
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 17 PLC/DCS Control Panel Design and Wiring
Schematics
Panel Design, layout and aesthetics
concept
Power Supply Sizing
Power Distribution Concepts
Earthing/IS Earthing Concepts
Wiring color Codes
Terminal arrangements
Inter-panel Wiring
Panel Lifting and transportation
requirements
Panel installation and commissioning
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 19 Panel mounted HMI Screen/Point
Development & Configuration
Compatibility with PLCs
Communication protocols
Size selection and panel touch facility
IP and Hazardous area requirements
Power Supply, EMI and environmental
requirements
CPU and memory Capacity
Programming Software capabilities
Data archiving and printing facility
Networking capability
Programming exercises
PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C
Session 18 Panel mounted HMI screen development
Exercises

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 20 Panel mounted HMI Screen/Point
Development Exercises

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 21 PLC Selection, Installation, Commissioning
and Trouble shooting
Application requirements
IO capacity requirements
Type of IOs needed
Size of memory
CPU Speed
Communication Requirement
Operator Interface
Physical Environments

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


Session 21 Review & Test

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C


DEMO Project
Given a set of P and I Ds and a layout of a mock project, the participants shall
prepare the following deliverable required for the project:

Mock KOM and preparation of KOM


minutes
Submit a Design Basis document for
approval
Prepare and submit Instrument Prepare Instrument/JB location plan

Index Prepare cable block diagram



Prepare and submit IO Schedule Prepare Cable schedule
Prepare Instrument Tray Layout drawings
Prepare Specification for a
Prepare Hook up and Instrument Installation drawings
PLC/SCADA system
Prepare JB and control panel termination drawings
Prepare datasheets for field Prepare Loop schematics
instruments
Submit calculation reports for power
and instrument air requirements
Prepare the Control logic write up
WILL GIVE OUR BEST

PLC/SCADA System Engineering and Programming VEPA INTEC MODULE C