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INDUSTRIAL AUTOMATION 6 Month Industrial Training Synopsis At FOXICON ENGINEERING Submitted in Partial fulfillment of requirement for award of degree Of

BACHELOR OF ENGINEERING 2009-2012 IN

ELECTRICAL AND ELECTRONICS COMMUNICATION ENGINEERING Duration of training Jan 2012- June 2012

SUBMITTED TO: -

SUBMITTED BY:SURAJ

(LC08570)

EECE 8TH SEM

CHANDIGARH COLLEGE OF ENGINEERING & TECHNOLOGY SECTOR - 26, CHANDIGARH – 160019

INTRODUCTION OF THE ORGANISATION FOXICON ENGINEERING IS a knowledge based independent engineering consultancy commited to bring a wide range of professional services for all phases of project development. We provide design engineering of plants for Oil & Gas, Chemical, Petrochemical, Fertilizer, Refinery, & Pharmaceutical industries. We are among the few engineering organization which provides Engineering design, Construction Management and Quality Management services to Residential, Commercial and Industrial sectors. We have developed fast response, capable and efficient resource group to provide quality service to our esteemend clients. We have the capability and talent to assist in developing the most basic ideas into workable designs with our team of experience engineers. We are well conversant with national and international codes and standards for carrying out various engineering activites. We follow ISO 9001 standards while offering high quality services and value driven. We focus on the quality of service and timely completion of all projects undertaken by us. Client satisfaction is top priority of every concerned member of the company, employee and the process of every project. FOXICON ENGINEERING firmly believes your project derseves nothing but best from us.

AUTOMATION INDUSTRY Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well. Automation plays an increasingly important role in the world economy and in daily experience. Automation has had a notable impact in a wide range of industries beyond manufacturing (where it began). Once-ubiquitous telephone operators have been replaced largely by automated telephone switchboards and answering machines. Medical processes such as primary screening in electrocardiography or radiography and laboratory analysis of human genes, sera, cells, and tissues are carried out at much greater speed and accuracy by automated systems. Automated teller machines have reduced the need for bank visits to obtain cash and carry out transactions. In general, automation has been responsible for the shift in the world economy from industrial jobs to service jobs in the 20th and 21st centuries.

RELIABILITY AND PRECISION The old focus on using automation simply to increase productivity and reduce costs was seen to be short-sighted, because it is also necessary to provide a skilled workforce who can make repairs and manage the machinery. Moreover, the initial costs of automation were high and often could not be recovered by the time entirely new manufacturing processes replaced the old. Automation is now often applied primarily to increase quality in the manufacturing process, where automation can increase quality substantially. For example, automobile and truck pistons used to be installed into engines manually. This is rapidly being transitioned to automated machine installation, because the error rate for manual installment was around 1-1.5%, but has been reduced to 0.00001% with automation.

AUTOMATED HIGHWAY SYSTEMS Full automation commonly defined as requiring no control or very limited control by the driver; such automation would be accomplished through a combination of sensor, computer, and communications systems in vehicles and along the roadway. Fully automated driving would, in theory, allow closer vehicle spacing and higher speeds, which could enhance traffic capacity in places where additional road building is physically impossible, politically unacceptable, or prohibitively expensive. Automated controls also might enhance road safety by reducing the opportunity for driver error,

which causes a large share of motor vehicle crashes. Other potential benefits include improved air quality (as a result of more-efficient traffic flows), increased fuel economy, and spin-off technologies generated during research and development related to automated highway systems.

AUTOMATED MANUFACTURING Automated manufacturing refers to the application of automation to produce things in the factory way. Most of the advantages of the automation technology has its influence in the manufacture processes. The main advantages of automated manufacturing are higher consistency and quality, reduced lead times, simplified production, reduced handling, improved work flow, and increased worker morale when a good implementation of the automation is made.

HOME AUTOMATION Home automation (also called domestics) designates an emerging practice of increased automation of household appliances and features in residential dwellings, particularly through electronic means that allow for things impracticable, overly expensive or simply not possible in recent past decades.

INDUSTRIAL AUTOMATION Industrial automation deals with the optimization of energy-efficient drive systems by precise measurement and control technologies. Nowadays energy efficiency in industrial processes are becoming more and more relevant. Semiconductor companies like Infineon Technologies are offering 8-bit microcontroller applications for example found in motor controls, general purpose pumps, fans, and bikes to reduce energy consumption and thus increase efficiency. One of 8-bit product line found in industrial automation is the XC800 family.

INTRODUCTION OF THE PROJECT

PROGRAMMABLE LOGIC CONTROL                               

Introduction to PLC Scope of Automation Role of PLC in automation PLC Architecture PLC Hardware Electrical Wiring Types of inputs-Outputs Source / Sink concepts Force On / Off Boolean Logic Design Simple Design Cases PLC Operation (Scan Cycle, Status, Memory types) Introduction to Ladder Logic Introduction to PLC programming software

, & Monitoring program Latches, Timer, Counter & More Online editing Addressing concept Structured Logic Design Flowchart Based Design Numbers & Data types Bit, Byte & Word concept Data Conversion instruction Floating point calculation PLC Memory Use of Internal Memory Importing & Exporting Data memory of project Ladder Logic Function Adv. Ladder Function Function Block Programming Anaput & Output

SCADA MODULES            

INTRODUCTION Role of SCADA in Automation Selection criteria of SCADA Creating a new SCADA project Developing Tag database Animation editing Creating Alarms Trends & Graphs Data Logging Communication protocol Communication with PLC Real time & historical trends

DRIVES MODULES          

Role of VFD in Automation Types of drives Selection of AC Drives Schematic diagram of VFD Configuration of basic parameters Local / Remote configuration Advanced VFD parameters Application Study RS484, Modbus Communication with PLC, HMI Drive Synchronization

INSTRUMENTATION AND SENSORS  Types of Sensors  Digital & Continuous sensors  Angular, Linear, Encoder, Force, Flow, Temperature, Light

& Chemical  Input issues  Sensor selection  Continuous Actuators

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Control of logical Actuators Control system Proportional Controllers PID Controllers Design Cases Connecting with PLC Installation of instrument

DESIGN MODULE           

Importance of Control Conventional Control & it’s difficulties PLC and its Advantages Conversion of conventional control circuit to PLC Systematic approach of control system design Relay Logic control system Study of MCCB, RCB, MPCB, ors Electrical & JIC symbols Study of IP standards Fail Safe design Calculation of size

HMI MODULE          

INTRODUCTION Types of HMI Communication with PLC Control / Notify Area concept Creating a project Types of screen Object Menu (lines, bulb, polygon, pipes, motors) Animation of objects Alarm banner & message display Documenting the Project

PLANNING OF WORK

FIRST MONTH PLC MODULES

SECOND MONTH SCADA MODULES

THIRD MONTH DRIVE MODULES

FORTH MONTH INSTRUMENTATION AND SENSORS

FIFTH MONTH DESIGN MODULE

SIXTH MONTH HMI MODULES

BENEFITS OF THE TRAINING

1. Industrial automation and process control greatly reduces the need for human sensory and mental requirements as well. Most complex industrial automation processes and systems can be automated. 2. A major advantage of industrial automation and process control is the increased emphasis on flexibility and convertibility in the manufacturing process. 3. Practical knowledge of industry 4. Opportunity to Work with professionals in field 5. On site training in industry 6. A major advantage of industrial automation technology is the latest developments.