KEC International Ltd.

zTulsiramji

Report of Industrial Training Program

on

PLC, SCADA & HMI

 A Report of
Industrial Training Program
On
PLC, SCADA & HMI
Submitted to

KEC International Ltd. Nagpur

For Partial Fulfillment of the Certificate of
Industrial Training Program

Submitted by

Mr. Aditya Badgujar.

Miss. Komal Gavhale.
Miss. Komal Patil.
Mr. Rahul Hiwale.
Mr. Shrikrushna Patil.
Students of
Padm. Dr. V. B. Kolte. College of Engineering, Malkapur.

Under the guidance of

Mr. Chetan Jambhulkar

Session 2021-22
 Content

1. Abstract

2. About KEC

3. Programs and opportunities

4. Methodologies

5. Learning Objectives/Internship Objectives

6. Day wise Overview of Internship Activities

7. Learning Outcomes

8. Conclusion
 Abstract

It is an immense pleasure for me to submit this training report as a part of “Diploma" in

“Electrical Engineering".I have taken my practical training of 45 days in “KEC International Ltd.
Nagpur."
I was exposed to real working environment and working condition in period of training.
I have maintained a training report and recorded day by day accounts of observation,
impression and information gathered from situation personal and technical literature.
This report describes about the“PLC , SCADA and HMI” in KEC International Ltd. On basis of
these collected information and guidance provide, I have prepared a comprehensive training
report.
 About KEC

KEC International Limited, headquartered in Mumbai, India, is the flagship company of the RPG
Group. A USD 1.8 billion Engineering, Procurement, and Construction (EPC) major, we deliver
projects in key infrastructure sectors such as Power Transmission & Distribution, Railways, Civil,
Urban Infrastructure, Solar, Smart Infrastructure, Oil & Gas Pipelines, and Cables.

Our robust and integrated capabilities span the entire EPC value chain from ‘concept to
commissioning’. We have successfully executed complex projects across some of the world’s
most difficult terrains and conditions, aided by robust engineering, procurement, execution and
project management capabilities. We have vast manufacturing footprint extending across India,
Dubai, Brazil and Mexico. Our global presence has enabled a robust and agile supply chain that
extends across six continents in over 105 countries.

For over 75 years, we have prided ourselves for our unmatched expertise in EPC, backed by a
strong customer-centric approach, quest for world-class quality, and ‘safety-first’ attitude.
Integrity in our actions and respect for people, environment and our stakeholders are the
cornerstones of our corporate responsibility. Empowered by a mindset driven to outperform
and excel, we build infrastructure for the world of tomorrow.
Programs and opportunities

PLC SCADA programmer is the key in Industrial automation, day by day IA is been implementing
in India and it would be great time soon for industrial Automation. PLC programmer should
have good logic knowledge and digital, analog knowledge. In every core industries like
machines, Oil Gas sectors, Process Industries every where PLC programmer is needed and good
pay also.

A PLC programmer designs control programs for electrical machines and systems, mostly in the
industrial sector and seeking to automate processes. For example, programmable controllers
are used to controlling machinery on factory assembly lines in the automobile industry.

Working as a PLC Programmer is one of the most attractive and highest paying jobs in the PLC
engineering industry. ... But someone like you, someone who believes in the true value of
working in this field and is committed to becoming a PLC programmer —the path to success is
wide open.

Nearly every modern factory uses PLCs to regulate the manufacturing process. This means that
the job outlook for PLC technicians and programmers is good. There is a strong and growing
demand for people with these skills. Compensation is also good with an average annual salary
of $61,000
Operators in manufacturing environments often have oversight over many pieces of
equipment. HMI and SCADA solutions allow them to precisely monitor, control, and visualize
every aspect of their operations in a centralized manner. With a quick glance, operators know
what's important and the right actions to drive increased efficiency and reduced costs. Latest
trends in industrial automation include increased use of analytics, growing use of PLCs, PACs,
and increased cloud-based supervisory control and data acquisition (SCADA) systems.
HMI(Human Machine Interface)These trends will influence the industrial automation control
market, according to a report.

HMIs enable control, management and/or visualization of device processes and can range from
simple inputs on a touch display to control panels for highly complex industrial automation
systems. ... Applications include industrial and building automation, digital signage, vending
machine, medical, automotive, and appliances.

We are seen the Programs and opportunity for PIC(programmable logic controller ) ,
SDADA(Supervisory control and data acquisition) , HMI(Human Machine Interface) ....
Methodologies

Method refers to the explanation of the topic to the students. The emphasis is on the
presentation of the content.

the illustrated lecture, where the speaker relies on visual aids to convey an idea to the students,
the briefing type of lecture, where the speaker presents the information without any elaborate
material to support the ideas.

Lectures across different categories work together. Thus, an instructor may give a semiformal,
problem-solving, chalk and talk lecture, while another may offer a lecture-discussion, point-by-
point, multimedia lecture.

1)Opening State the purpose of the lecture. Use generalized statements to capture the
focused attention of the students. Multi-media resources

2) Presentation Elaboration Multi-media resources

3) Learner-Instructor two-way Interaction Encouraging active learning Multi-media streaming

4) Formative Assessment drives better learning and performance Multi-media devices

5) Conclusions Consolidating the concepts

Learning Objectives/Internship Objective.

The main objective of PLC and SCADA workshop is to make aspiring engineers acquainted with
the conceptual and practical knowledge of the industrial automation and latest technologies
being used to achieve industrial automation.

The idea of organizing this workshop is to incalculate the basic fundamental of automation in
the student and provide them with a platform to work on, in the near future.

Set goals for trainees to achieve in steps towards a large outcome, such as mastering technical
skills.

Each objective should be clear and concise. Think about what you want to gain from this
internship experience. Setting goals and learning objectives provides a means for evaluation of
your experience. Writing the learning objectives is a collaborative effort between you and your
faculty advisor.

Develop and improve business skills in communication, technology, quantitative reasoning, and
teamwork. Observe and participate in business operations and decision-making. Meet
professional role models and potential mentors who can provide guidance, feedback, and
support.The Learning objective or objectives that you use can be based on three areas of
learning: knowledge, skills and attitudes. They help you and your students evaluate progress
and encourage them to take responsibility for their learning.

Identify the Level of Knowledge Necessary to Achieve Your Objective. ...

Overview of Internship Activities

What is PLC

A PLC (Programmable Logic Controllers) is an industrial computer used to

monitor inputs, and depending upon their state make decisions based on its program or logic,
to control (turn on/off) its outputs to automate a machine or a process.

◆ Traditional PLC Applications

 1. In automated system, PLC controller is usually the central part of a process control system.
2. To run more complex processes it is possible to connect more PLC controllers to a central
computer.

◆ PLC History
PLC development began in 1968 in response to a request from an US car
manufacturer (GE). The first PLCs were installed in industry in 1969.
Communications abilities began to appear in approximately 1973. They could also be used in
the 70’s to send and receive varying voltages to allow them to enter the analog world.

◆ PLC Hardware
Hardware Components of a PLC System
Central Processing Unit (CPU), Memory, Input /Output, Power supply unit,
Programming device.

◆ PLC Operation
 Input Relay
 Output Relay
 Internal Utility Relay
 Counters
 Timers
 Data Storage

◆ PLC Communications
 Extension modules
 Remote I/O connections
 Remote PLC's
 Cables
 Serial and Parallel communication
 Serial and Parallel standards
 ASCII
 protocols
◆ RS-232 Comuunication with PLC
RS-232 is a communication standard published by the EIA.

The RS-232 standard defines:

The different signals in the RS-232 link.
The electrical requirements of the signals.
The connector type and pin layout.
In PLC Device communications, RS-232 is used to create a point to point link.

◆ RS-485 interface
RS-485 is an industrial specification that defines the electrical interface and physical layer for
point-to-point communication of electrical devices. The RS-485 standard allows for long cabling
distances in electrically noisy environments and can support multiple devices on the same bus.

◆ PLC Input Units

An input device is a piece of computer hardware equipment used to provide data, and control
signals to an information processing system (IPS).
Some examples of input devices include:

 Switches and push buttons

 Sensing devices
 Limit switches
 Proximity sensors
 Photoelectric Sensors
 Condition sensors
 Vacuum switches
 Temperature switches
 Level switches
 Pressure switches

◆ PLC Output Units

  An output device is any piece of hardware used to communicate the results of data
processing carried out by an IPS, and translate the information into an understandable
form.

 Valves
 Motor starters
 Horns and alarms
 Stack lights
 Control relays
 Pumps
 Printers
 Fans

◆ PLC selection criteria

It consist of :-
 System (task) requirements.
 Application requirements.
 What input/output capacity is required?
 What type of inputs/outputs are required?
 What size of memory is required?
 What speed is required of the CPU?
 Electrical requirements.
 Speed of operation.
 Communication requirements.
 Software.
 Operator interface.
 Physical environments.
What is SCADA ?
The term SCADA stands for Supervisory Control And Data Acquisition. A SCADA system is a
common process automation system which is used to gather data from sensors and
instruments located at remote sites and to transmit and display this data at a central site for
control or monitoring purposes. The collected data is usually viewed on one or more SCADA
Host computers located at the central or master site.

SCADA system is consist of 3 main elements :-

1. RTU ( Remote Technology Unit )

2. HMI (Human Machine Interface )
3. Communication

◆ SCADA Communications
SCADA communications can employ a diverse range of both wired (lease line, dial-up line, fiber,
ADSL, cable) and wireless media (licensed radio, spread spectrum, cellular, WLAN or satellite).
The choice depends on a number of factors that characterize the clients existing
communication infrastructure.
Factors such as existing communications infrastructure, available communications at the
remote sites, data rates and polling frequency, remoteness of site, installation budget and
ability to accommodate future needs all impact the final decision. In complex SCADA
architectures, there can be a variety of both wired and wireless media and protocols involved
to get data back to the central monitoring site.

HMI ( Human Machine Interface):

What is the very first thing that comes to your mind when you think about Human Machine
Interface? Is it some kind of interaction which takes place between a machine and a human
being or is it a common cloud where every non-living entity is capable of interacting as well as
associating with every living entity? Well, the first thing which usually strikes our mind when we
talk about Human Machine Interface (HMI) is a kind of interaction which is a property of several
devices which are designed in such a way that they are capable of handling human to machine
as well as machine to human interactions with utmost ease as well as reliability.

A Human Machine Interface basically, is a well- structured combination of hardware and

software components which enable all users to provide inputs which later on gets converted
into signals by these machines.

◆ How HMI Works ?

Human machine interfaces (HMIs) are used as an operator control panel to PLCs, RTUs, and in
some cases directly to IEDs. HMIs replace manually activated switches, dials, and other controls
with graphical representations of the control process and digital controls to influence that
process. HMIs allow operators to start and stop cycles, adjust set points, and perform other
functions required to adjust and interact with a control process. Because the HMI is software
based, they replace physical wires and controls with software parameters, allowing them to be
adapted and adjusted very easily.

◆ Features of HMI

 High image quality

 Clear screen without grid
 Multi language
 Alarm function
 Support various fonts and graphics
 Security enhanced with password protection
  Varil is built in interfaces

◆ HMI Diagram
◆ PLC / SCADA / HMI Controller
Learning Outcomes

At both the course and program level, student learning outcomes should be clear, observable
and measurable, and reflect what will be included in the course or program requirements
(assignments, exams, projects, etc.). Typically there are 3-7 course learning outcomes and 3-7
program learning outcomes.

Industrial Training is to experience and understand real life situations in industrial organizations
and their related environments and accelerating the learning process of how student's
knowledge could be used in a realistic way.

To integrate theory with practice.

To introduce students to work culture and Industrial practice.

To give opportunity to student to work with industrial practitioners.

To expose students potential employes.

Practical ethical professional work culture.

 Conclusion

In the corporate world a technocrat is judged not only on the basis of technical knowledge but
also on his problem solving efficiency planning and ability to work in a team exposure of
technical knowledge to real world problem makes a man professional conversant with the
complexities involved in a job. In view of such benefits , practical training has been made an
integral part of my curriculum.

The weeks of my first practical training were full of wonderful experience. Training has made
me well acquainted with the necessities and the problems that engineers actually face during
their jobs . It has also helped me a lot to adapt myself to actual working environment and
working co- ordination with other team members.

This training helped me a lot in exchanging my inter and personal skills there by furnishing my
attitude, skill and knowledge. Further the guidance , support , co- operation and assistance
provided by my colleagues and members at the bank helped me a lot in developing the project.