Application of PLC SCADA in industries

Application of PLCs in process and manufacturing industries

PLC SCADA systems are used for automating process and manufacturing /assembly lines. Process means step-by-step procedure sequence, whereby a particular product is manufactured and assembled. Product engineering department is responsible for manufacturing plan of new or modified products. Some other PLC SCADA systems may be controlling sequences/ processes, which might involve filling/ capping/labeling/packaging of bottles, the printing of newspapers, or the automobile assembly lines etc. In many such manufacturing situations, PLC SCADA play very important role in carrying out the process.

Advantages of PLC systems

• PLC systems have highest Reliability in operation
• Control systems have flexibility in modifying PLC logics
• Flexibility in PLC programming and reprogramming
• large contacts in small package
• PLC systems are very cost effective for complex control systems
• Small size but speedy operation
• PLC systems can communicate with other control systems & computer systems in the plant.
• PLC controlled systems have ease of maintenance troubleshooting
• Proper documentation & high level of Security

The PLC system is so designed that it can operate in the industrial environment having robust ambient temperature, vibration, and humidity. PLC systems are immune to electrical noise. PLC systems have fault indicators, fuse status indicators, input/output status lights, and written fault information displayed on the programmer. Therefore PLC systems are easy control systems for troubleshooting. Personal computers/Laptops are used for programming/monitoring PLC systems.

Number System in PLC

PLC is just like a computer, it therefore stores information in the form of On or Off conditions referred to as binary digits (bits).

Difference between PLC systems and PCs

PCs are generally data processing computers. Such computer systems process and analyze a large data, store this database, generate report and display the data/information to operators.

PLC system is generally a process control computer; small, manufactured to work in harsh environment and it is also easy to program, maintain and repair. PLC System can handle real time data and input output tasks whereas computers can handle non-real time tasks. PLC systems are generally installed near to the machine or process they control, and are generally considered as an extension part of a industrial equipment.

PLC Architecture

PLC system consists of various sections, each designed for certain functions: like CPU, Input module, output module, communication bus, memory, power supply.

CPU
There are two types of PLC systems used in industry: fixed and modular. CPU unit of PLC system is built into a single-piece unit in fixed PLC. While in modular PLC’s, the CPU is a plug-in module. CPU functions same as brain functions in human body. CPU has a microprocessor integrated chip which is placed on a PCB with associated interface chips.

Microprocessor which is the brain of a PLC system supervises all functions in a PLC System. CPU reads position/ information of input devices and stores this information in the memory for later use. Then it executes the user program and then updates the output devices / field hardware devices.

PLC Memory System
This is as storage for the user program. The input status file consists of memory location and stores the status of each field input device. The output status file consists of memory locations and stores the status of field hardware devices after the user program is executed. The output module is a kind of switching device for each output point. The data storage area of memory is used to store numerical/math calculation related data.

PLC I/O Module
There are two types of real world input and output devices: Discrete and analog. Discrete devices are either ON or OFF type. Limit switches, push button, pilot lamps, solenoids etc. are the examples of discrete input devices. Analog devices cater to a continuously varying quantity between minimum to maximum such as temperature, Pressure, level, flow etc.

PLC INPUT MODULES
Input modules in a PLC system serve as the link between field devices and the PLC CPU. Input modules have a terminal blocks for attaching input wiring from each individual field input device. The function of an input module is to read input signals, convert it to a signal level CPU can understand and send the signal, back to the CPU. Each input terminal on each input module has one memory location in the input status file. Which stores the binary equivalent of the ON or OFF status either 0 or 1.

PLC OUTPUT MODULES
Output Modules in PLC system serve as the link between the PLC¢s microprocessor and field devices. PLC output module has a terminals for attaching output devices. Generally output modules have 8, 16, 32, 64 output terminals.

Remote PLC I/O Racks
Generally PLC input and output modules are installed closer to the actual operating equipment. Which saves lot of cable and other associated wiring/ labor cost. PLC output modules have status lights which shortens troubleshooting time and increases production, eases maintenance and efficiency of the system.

PLC Training, PLC SCADA Training courses by Sofcon India Pvt Ltd greatly help budding engineers understand practical application of automation system.

FIXED AND MODULAR PLC HARDWARE

PLC hardware falls into two physical configurations

Fixed PLC: A fixed PLC system has all of its components positioned in single unit.. This style of PLC system is also called a packaged controller.

Modular PLC:-The modular PLC system comes as modular pieces. 

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Skill India: Myriads of Job Opportunity

B.Tech fresher’s who passed out their engineering in Electrical & Electronics, Electronics and Communication, Instrumentation and Control, Mechanical & Automation Engineering should convert this golden opportunity to make their career in the core field of Industrial Automation, Building Automation, Embedded System and VLSI, HVAC Control & HVAC Design and Draughting.

Migration of Non CS/IT students into IT or ITES field should be an alternative choice of the fresher because of his passion and love for computer science and IT and not because of unavailability of opportunities and lack of employment.

Sofcon Group is bridging the gap between academics and industry since 2006 and successfully placing the students since its inception. After the affiliation of Sofcon, with NSDC and other sector skill councils, our pledge to provide employment to the students irrespective of their academic, social or financial status has become strengthened.

Courses with 100% placement assurance for B.Tech EE/EC/EI are:

Industrial Automation: PLC/SCADA, Motion Control (Motors and Drives), Panel Designing, Auto CAD, Process Instrumentation, HMI, DCS, Industrial Network & Wireless Network.

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Protecting Industrial automation control systems from Hacking

In the last few years activities of hackers have intensified, they have infiltrated information of credit cards, health care providers, retailers and other consumer industries. Cashless transactions/e-payments are basically for making the life easier, but hackers use the very technology in contrary. They gain access to our private information and financial accounts. As a result, innovative cyber security providers are constantly improving their defence technologies to keep up with the ever-changing threat.

Companies are also increasing their investments in Industrial automation control technologies in protecting vital information from the cyber threats. These systems control our power supply & distribution, water management, process & manufacturing plants, oil refineries, transportation etc. These systems have faced less of a threat simply because they were often isolated from business networks and utilized proprietary technologies. But today more and more companies are looking to gain the efficiency of remote access or utilize the Internet of Things (IoT) to improve performance. Furthermore, newer ICS Industrial automation control systems are employing open standard communication protocols. As a result, these systems have become major targets for cyber attacks.

Industrial automation control system (ICS) cyber security: The purpose of this paper is to present a cyber security framework. Readers of this document should be familiar with general ICS Industrial automation control systems components and design, cyber security concepts and communication protocols. Critical infrastructure providers are under attack, with 36% of firms experiencing at least one operational disruption in the past two years. The cyber threat to the world’s critical infrastructure is real.

First, the potential impact of cyber infiltration is serious and damaging issue and hackers know this. Cyber attack can cause significant economic harm, but can also threaten health, safety and lives.

Third: Sixty-eight percent industries claimed that they faced several cyber security breaches. 35% said cyber security incidents led to a disruption of operations. DCS is a control system that is developed to replace PID controllers and are used primarily to control production systems whereas PLC systems are generally used to control specific applications and/or standalone equipment and can be used in both SCADA and DCS systems. Leading companies such as McAfee, HP, Tripwire, Symantec and IBM, as well as thousands of start-ups are investing billions in R&D to stop the next innovative hacker. 

 

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