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Installation/programming of Control System and Design of PLC system.

Project done and handed over.

The main difference between PLC and RTU is that PLC is short for programmable logic controller , it is suitable for local control like amusement rides, assembly lines, etc… , PLC used IEC 61131-3 it is cheaper in comparison to RTUs and PLC requires local processing
Whereas RTU is short for remote terminal units, it is suitable for wider geographical telemetry since they use wireless communication. RTU usually uses other alternative proprietary tools, it’s require little to no processing.
RTU does not support control loops or control algorithms. Because of cheaper technology. In RTU, the data from this controller is then transferred to SCADA systems or any other higher level of graphics control systems. RTU is specifically designed for remote IO applications where the IO’s are distributed far in the plant and data needs to be transferred in a wireless manner So, it is more rough and tough to use and has more efficiency than a PLC.
The speed of data transfer is faster in a PLC than in an RTU. Also, all the process data and programming data will be communicated in a PLC.
But, in RTU, only requested data and changes in it will be communicated. Basically, in a PLC, the programs are driven in a cyclic manner, and in an RTU, the programs are driven in an event manner. As the RTU does not have an in-built display and also, program control is much less in it; a SCADA is generally used everywhere when an RTU is used.
But, a PLC does not compulsorily require a SCADA; as many controllers nowadays have an in-built display, and also if not, the program control is much stronger in it to avoid its necessity. The operator can properly control the plant by means of hardwiring buttons.

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HART transmitter calibration procedure.The microprocessor of the instrument measures some electrical properties that are affected by the process variable of interest. The measured value can be millivolts, capacitance, reluctance, inductance, frequency or some other property



A temperature controller is an instrument used to control temperature calculating the difference between a setpoint and a measured temperature. The controller takes an input from a temperature sensor and has an output that is connected to a control element such as a heater or fan.

The compact temperature controllers from WIKA offer display, control and monitoring of temperatures. The configuration of the sensor input is made via the multi-function input. Sensors, thermocouples and standard industrial signals, such as 4 ... 20 mA, serve as the input variable of a temperature controller. The control output can be set either as relay (for slow control), as logic level for the control of electronic solid state relays (for fast control and high current loads) or as a continuous 4 ... 20 mA output.

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What is industrial control system (ICS) An industrial control system is a combination of a variety of systems like computers, electrical and mechanical devices. It can be considered as the combination of several control systems such as supervisory control and data acquisition (SCADA) systems, distributed control systems (DCS), and programmable logic .

They are used to provide automated or partially automated control of the equipment in manufacturing and chemical plants, electric utilities, distribution and transportation systems, and many other industries. It can also be described as the automatic regulation of unit operations and their associated equipment as well as the integration and coordination of the unit operations into the larger production system. ICS is used in manufacturing operations and it can also be applied to material handling.

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last week siemens is celebrating the 25th anniversary to launch LOGO smart relay. which is used in many Automation projects around the world and has become the newer version of it has very amazing capabilities.
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Easy way to learn and simulate PLC/SCADA System by Modbus.

What is Modbus ?

Modbus is a data communications protocol originally published by Modicon (now Schneider Electric) there is in Serial communication such as ( CAN BUS System used in cars ) and communications between PLC Modules and I/O further away. The PLC Modules is the Master which require specific orders from the slave or from sub-units. each unit has specific address. Modbus is often used to connect a plant/system supervisory computer with a remote terminal unit (RTU) in (SCADA) systems.

Modbus is become a standard serial communication between unites for distance up to 1000m and before using repeater data was sent in the form packet with capacity 254 MB/PCK
Modbus Protocols
• Modbus ASCII
• Modbus RTU (Remote Terminal Unit)
– Modbus RTU uses RS-485 or RS-232.
• Modbus TCP/IP.
– Modbus TCP uses Ethernet.
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what is the deferent between PROFIBUS DP VS PROFIBUS PA ?

PROFIBUS is a 2-wire industrial data communication standard (fieldbus) that allows components such as sensors, actuators and controllers to exchange process values and achieve the automation of a complete process. Thousands of different products offered by hundreds of suppliers provide a solid foundation to utilize PROFIBUS for every automation application.

There are two variations of PROFIBUS in use today; the most commonly used PROFIBUS DP, and the lesser used, application specific, PROFIBUS PA.

PROFIBUS DP (Decentralised Peripherals) is used to operate sensors and actuators via a centralised controller in production (factory) automation applications.it uses two core screened cable with a violet sheath, and runs at speeds between 9.6 kbit/s and 12 Mbit/s.The physical layer for PROFIBUS DP is RS-485.If RS-485 transmission technology is used, all field devices are typically connected in a line structure with up to 32 nodes in one segment.The beginning and end of each segment are provided with active bus termination and power. If there are more than 32 nodes or the network span is being extended, repeaters must be used to link the networks.

PROFIBUS PA (Process Automation) is used to monitor measuring equipment via a process control system in process automation applications.it runs at fixed speed of 31.25 kbit/s via blue sheathed two core screened cable.The physical layer of PROFIBUS PA is Manchester Encoded Bus Powered (MBP).If MBP transmission technology is used (in process automation), basically, any topology is permissible. Linear and tree structures and combinations of both are thus possible. In practice, the “trunk & spur topology” has established itself as the de-facto standard, as it is especially clear and well-laid-out.

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What is the Difference between VFD and Soft Starter?
Variable frequency drives and soft starters are used in industrial motor control and pump control.
The main difference between the two is that a VFD can increase/decrease the speed of a motor while a soft starter only controls the starting and stopping of that motor. When faced with an application, price and size are in the favor of a soft starter. A VFD is the better choice if speed control is required.

VFD’S have three main components
A rectifier, a filter, and an inverter
The rectifier acts like diodes, takes the incoming AC voltage and changes it to DC voltage, next the filter uses capacitors to clean the DC voltage making it a smoother incoming power, finally, the “inverter” uses transistors to convert the DC voltage and sends the motor a frequency in hertz, this frequency drivers the motor to a specific RPM.

Soft starter
3 phase soft starter uses six thyristors or silicone-controlled rectifiers Oriented in an anti parallel configuration to start the electric motors smoothly, The motor, attached to the soft starter, will start up at a nice smooth current, and top out, at the preset maximum speed, the motor will stay at that speed unit we stop the motor
Where the soft starter will ramp down the motor in a very similar way as the ramp-up.

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What is the plc ?

PLC stands for “Programmable Logic Controller”" PLC is an electronic digital device which use a programable memory for instructions storage depending on the inputs and outputs. plc is used to automate industrial processes such as a manufacturing plant’s such as processing plant and a wastewater treatment plan.

PLC consists of five parts namely:

Rack
Power Supply Module
Central Processing Unit (CPU)
Memory: ROM memory includes an operating system, drivers, and application programs.
Input & Output Module: Input module interface receives the signal from process devices (DI switches ,AI transmitters).
Communication Interface Module.

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