Lab Manual: Fourth Year Semester-VII

Lab Manual
Fourth Year Semester-VII

Instrumentation Engineering
Subject: Process Automation
Odd Semester
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Institutional Vision, Mission and Quality Policy
Our Vision
To foster and permeate higher and quality education with value added engineering, technology
programs, providing all facilities in terms of technology and platforms for all round development with
societal awareness and nurture the youth with international competencies and exemplary level of
employability even under highly competitive environment so that they are innovative adaptable and
capable of handling problems faced by our country and world at large.
RAIT’s firm belief in new form of engineering education that lays equal stress on academics and
leadership building extracurricular skills has been a major contribution to the success of RAIT as one
of the most reputed institution of higher learning. The challenges faced by our country and world in
the 21 Century needs a whole new range of thought and action leaders, which a conventional
educational system in engineering disciplines are ill equipped to produce. Our reputation in providing
good engineering education with additional life skills ensure that high grade and highly motivated
students join us. Our laboratories and practical sessions reflect the latest that is being followed in the
Industry. The project works and summer projects make our students adept at handling the real life
problems and be Industry ready. Our students are well placed in the Industry and their performance
makes reputed companies visit us with renewed demands and vigour.
Our Mission
The Institution is committed to mobilize the resources and equip itself with men and materials of
excellence thereby ensuring that the Institution becomes pivotal center of service to Industry,
academia, and society with the latest technology. RAIT engages different platforms such as
technology enhancing Student Technical Societies, Cultural platforms, Sports excellence centers,
Entrepreneurial Development Centre and Societal Interaction Cell. To develop the college to become
an autonomous Institution & deemed university at the earliest with facilities for advanced research
and development programs on par with international standards. To invite international and reputed
national Institutions and Universities to collaborate with our institution on the issues of common
interest of teaching and learning sophistication.
RAIT’s Mission is to produce engineering and technology professionals who are innovative and
inspiring thought leaders, adept at solving problems faced by our nation and world by providing
quality education.
The Institute is working closely with all stake holders like industry, academia to foster knowledge
generation, acquisition, dissemination using best available resources to address the great challenges
being faced by our country and World. RAIT is fully dedicated to provide its students skills that make
them leaders and solution providers and are Industry ready when they graduate from the Institution.
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We at RAIT assure our main stakeholders of students 100% quality for the programmes we deliver.
This quality assurance stems from the teaching and learning processes we have at work at our campus
and the teachers who are handpicked from reputed institutions IIT/NIT/MU, etc. and they inspire the
students to be innovative in thinking and practical in approach. We have installed internal procedures
to better skills set of instructors by sending them to training courses, workshops, seminars and
conferences. We have also a full fledged course curriculum and deliveries planned in advance for a
structured semester long programme. We have well developed feedback system employers, alumni,
students and parents from to fine tune Learning and Teaching processes. These tools help us to ensure
same quality of teaching independent of any individual instructor. Each classroom is equipped with
Internet and other digital learning resources.
The effective learning process in the campus comprises a clean and stimulating classroom
environment and availability of lecture notes and digital resources prepared by instructor from the
comfort of home. In addition student is provided with good number of assignments that would trigger
his thinking process. The testing process involves an objective test paper that would gauge the
understanding of concepts by the students. The quality assurance process also ensures that the
learning process is effective. The summer internships and project work based training ensure learning
process to include practical and industry relevant aspects. Various technical events, seminars and
conferences make the student learning complete.
Our Quality Policy
Our Quality Policy
It is our earnest endeavour to produce high quality engineering professionals who are
innovative and inspiring, thought and action leaders, competent to solve problems
faced by society, nation and world at large by striving towards very high standards in
learning, teaching and training methodologies.
Our Motto: If it is not of quality, it is NOT RAIT!
Dr. Vijay D. Patil

President, RAES
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Departmental Vision, Mission
Vision
To be a premier department for the study of Instrumentation Engineering through maintaining

high quality academic standards, state of art resources and teaching that promotes students to
achieve competencies, exemplary level of employability, analytical thinking and independent
judgment necessary to function responsibly and successfully in a highly competitive
professional and global society.
Mission
 Creating knowledge of fundamental principles and innovative technologies through

research within the automation and control areas of Instrumentation and in
collaboration with other disciplines that is distinguished by its impact on academia,
industry and society.
 Educating future leaders in academia, industry, and entrepreneurial pursuit, through a
curriculum of theory and application that develops the ability to solve problems
individually and in teams.
 Serving the communities to which we belong, at local, national, and international
levels, combined with a deep awareness of our ethical responsibilities to our
profession and society.
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Index
Sr. No. Contents Page No.
1. List of Experiments 6
2. Experiment Plan and Course Outcomes 7
3. Study and Evaluation Scheme 8
4. Experiment No. 1 9
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List of Experiments
Sr. No. Experiments Name
Introduction to Programmable Logic Controller (PLC) Simulator Kit.
1
To study PLC input and output symbols.
2
Verification of pneumatic applications using PLC.
3
To write a program for switching two lamps.
4
To write a program to fill the two tanks with water.
5
To write a program for Conveyor belt application.
6
To write a program for car parking application
7
To study Distributed Control System(DCS) programming using Function Block
8 Diagram method
GUI development for any one application using SCADA software.

9
Special Experiments as Case Studies
10
6
Experiment Plan & Course Outcome
Course Outcomes:
CO1 Define automation, it’s importance, expectations from automation and

applications in industry.
CO2 Understand working of PLC, I/O modules of PLC, Programming languages and
instructions of PLC, design PLC based application by proper selection and sizing
criteria, developing GUI and ladder program.
CO3 Understand evolution and architecture of DCS, hierarchical control in DCS,
programming DCS through Function Block Diagram (FBD) method.
CO4 SCADA architecture, communication in SCADA, develop any application based on
SCADA along with GUI using SCADA software.
CO5 To understand Philosophies of Alarm Management , Historian, MES
CO6 Understand the need of SIS, risk reduction methods, evaluation of SIL( Safety
Integrity Levels).
Module Week Course

Experiments Name
No. No. Outcome
Introduction to Programmable Logic Controller (PLC)
1 W1 Simulator Kit. CO1
To study PLC input and output symbols.

2 W2 CO2
Verification of pneumatic applications using PLC.

3 W3 CO2
To write a program for switching two lamps.

4 W4 CO2
To write a program to fill the two tanks with water.

5 W5 CO2, CO4
To write a program for Conveyor belt application.

6 W6 CO2, CO4
To write a program for car parking application CO2, CO4,

7 W7
CO3
To study Distributed Control System(DCS) programming
8 W8 using Function Block Diagram method CO3, CO5
GUI development for any one application using SCADA

9 W9 software. CO5, CO6
10 W10 Special Experiments as Case Studies
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Study and Evaluation Scheme
Course
Course Name Teaching Scheme Credits Assigned
Code
Theory Practical Tutorial Theory Practical Tutorial Total
Process
ISC704
Automation
04 02 -- 04 01 -- 05
Course Code Course Name Examination Scheme

Term Work Oral Total
Process
ISC704
Automation 25 25 50
Term Work:
1. Term work assessment must be based on the overall performance of the student with
every experiment graded from time to time. The grades should be converted into
marks as per the Credit and Grading System manual and should be added and
averaged.
2. The final certification and acceptance of term work ensures satisfactory performance
of laboratory work and minimum passing marks in term work.
Oral:
1. Oral exam will be based on the entire syllabus of Process Automation.
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Process Automation
Experiment No. : 1
Introduction to Programmable Logic

Controller (PLC)
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Experiment No. 1
1. Aim: Introduction to Programmable Logic Controller (PLC) Simulator Kit.
2. What will you learn by performing this experiment?
Simulator kit introduction will help students to understand the basic information of PLC.
Further students can perform well with all hardware and software information.
3. Hardware Required: Allen Bradley Micro logix 1400 series A PLC Simulation Kit,
PC, RS 232 or Ethernet cable for communication and wires.
4. Theory:
A programmable controller or programmable logic controller (PLC) is a device, which is

capable of being programmed to perform a controlling function. These system were very
flexible in design and easy for maintenance personnel to understand However, they involved
a vast amount of interconnection from relay to relay, and logic block. This led to the
development of the Control panel concept for larger and more complex logic control system.
Adopting the ladder diagram programming language, simplifying maintenance, and reducing
the cost of spare parts inventories realized major advantages. Also, PLCs allowed for shorter
installation time and faster commissioning through programming rather than wiring. In 1968,
the prime focus of programmable controller was simply to replace relays. In relay logic
diagrams, a contact is either closed or open. There are presently over so many different
manufacturers of programmable controllers like Siemens, Allen, Bradley, Mitsubishi, LG,
Toshiba, etc. All machine share a number of similarities. We study some of the common
features of PLCs. The Block diagram representation of PLC is given below:
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Components of PLC
1. Input sensing devices

2. Input Module
3. CPU
4. Programming Device
5. Output Module
6. Output device
Power supply
The power supply provides all the voltage levels needed to operate the
PLC. The power converts 120 v or 240v ac into the dc voltage required by the CPU, the
memory, and I/O modules.
Input module
It is a device to interface in between the input device to CPU. The input

interface provides the connection to the machine or processed being controlled. The
principle function of this interface is to receive and convert field signals(push button,
limit switch, proximity switch , circuit breaker, relay etc.) into a form that can be used by
the CPU.
A typical discrete input module performs the following four task.
1. Sense the presence or absence of an input signal at each of its input terminal.
2. Converts an input signal to a level usable by the interface ‘s electronic circuit.
3. Electronically isolates the input and output stages of the module.
4. Produce an output to be sensed by the CPU with the electronics circuit.
5. Name of different input module:
1. Digital input module
2. Analog input module
3. RTD / thermocouple input module
4. Potentiometer input module
5. Interface RS 422/485 communication input module
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6. High speed counter input module
Output module
It is a device interfaced in between output memory to output device. The output

interface performs the opposite function of the input interface. The power supply
provides all the voltage levels needed to operate the PLC.
Name of different output module
1. Digital output module

2. Analog output module
3. Position control output module
CPU
All programmable controller’s have input and output interface, memory, a method of
programming, CPU, and power supply. A programmable controllers CPU performs the
same basic functions as the MPU in microcomputer. Consequently the terms processor
and microprocessor are used interchangeably. This function are shown in the function
block diag. the input interface provides a connection to the machine or process being
controlled.
The output interface performs the opposite function of the input interface. It takes signals
from the CPU and translates them into forms that are appropriate to produce control
action by external device such as solenoids, valves, motor starters, and so on
In order for a CPU to execute the program stored in memory, it must be to “ see” what is
occurring in various memory locations. Application program instruction and executing
the control program is referred to as the scan function of PLC.
The CPU is constantly interacting with system memory to interrupts and executes the
application program that controls the machine or process. The amount of time required
of the CPU to read the program stored in the RAM memory, execute the control program
and update all output is called scan time.
It is generally available in four modes
1. RUN mode.
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2. Program mode/remote mode
3. Halt or hold mode
4. Error mode
This modes selects using selector switch or software command.
MEMORY
The term memory utilization refers to the no of memory location required to

store each type of instruction. Two terms that often associated with plc memory are input
table and output table. These terms simply refer to a location where the status of an input
or output device is stored. If a PLC has 32 input connected at the i/o rack an input table
containing 32 bits would be required. Each bit is either a 1 or 0 depending on whether
input is open or closed.
Each PLC manufacturer uses a slightly different method of organizing the information
which is stored in memory of the plc. Although all PLC’s have similarities in their
memory structure such as RAM and ROM chips. The location where bits of information
are stored and the method the CPU uses to read this data can vary substantially.
Memory organization takes into account the plc divided the available memory into
different sections. Because ROM memory contains information that is not alterable, this
portion of memory is a fixed to quantity. However, application memory is usually quite
flexible in terms of how many bytes of information are allocated for any particular
function.
Typical PLC memory data
Factory configured data

Additional preset and accumulated bits
File or bits storage
Main program
Subroutines
Message storage area
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Programming terminal
Most PLC language are based on ladder logic which is advanced form of relay logic. In
addition to specifying contact closer types at coils, ladder logic program allow entry of
math function , analog control, complex counter, timer Operation function and sequential
control and so on. Alternative language use Boolean representation of this control
scheme as the base of computer representation.
A programming device, or programming terminal, allows a user to enter instructions into

memory in the form of a program. The programming device produces the pattern of
electrical signals that correspond to the symbols, letters or numbers entered by the user.
Programming device vary widely in complexity, ease of use, and cost. The can be handy
held unit, laptop or notebook microcomputer or desktop pc.
Input device
It gives the signal to PLC i.e. field signals from field push buttons, selector switch,
proximity switch, circuit breakers Relay & feedback signal etc.
Output device
Digital output signal control Indication solenoids Operation, valves Operation, motor
starters, control relays, Alarms, Lights and so on.
5. Results:
6. Conclusion and Discussion:
7. QUIZ / Viva Questions:
 What is Automation?
 Why Simulation is required?
 What is the power supply of PLC?
 Which are the analog I/Os connected to PLC?
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8. References:
1. Gary Dunning, “Introduction to Programmable Logic controller”, Thomas Learning,

edition, 2001.
2. Thomas Hughes, “Programmable Logic Controller”, ISA Publication.
3. Allen Bradley PLC standard user guide.
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Process Automation
Experiment No. : 2
To study PLC Input Output Symbols
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Experiment No. : 2
1. Aim: To study PLC input and output symbols.
Studying the symbols will help students to identify the types of inputs and outputs. Also
while performing the experiment student can connect I/Os properly with available remote
switches and push buttons.
3. Hardware Required: Allen Bradley Micro logix 1400 series A PLC Simulation Kit, PC,
RS 232 or Ethernet cable for communication and wires.
4. Theory: The type of programming used to program a PLC is called rung ladder logic due
to its form using various levels in the program. In each rung, commands are given which use
inputs and counter relays to determine the status of outputs and other counter relays. Some of
the important elements of ladder logic rungs will be shown here.
Basic Elements
The three basic elements are:
Normally opened contact

Normally closed contact
Boolean: = < >
Normally opened contact
A normally opened contact "energizes" or turns on the rung when the input is on. For
example in the following:
Y2 will turn on when X1 is sensed to be on by the CPU.
Normally closed contact
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A normally closed contact works just the opposite of a normally opened contact. In this
example:
Y2 will go on when X1 is sensed to be off.
Boolean Contact
A boolean contact compares the value of the input to a chosen value. The contact energizes
when the boolean expression is satisfied. In this example:
Y3 will energize when the value of V2000 (all V values are addresses for variables that can
be stored in the CPU) is equal to K4903 (all K values are constants).
Other Logic Elements
Timer
A timer waits a specified amount of time before it executes a command.
In this example when X1 goes true it starts the timer at the right. It counts in increments of
one tenth of a second so the timer above will wait three seconds (notice the K30) to energize
the Y0 output. The timer resets itself to false when the its input variable (X1 in this case)
becomes false.
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Counter
The "counter" simply counts the number of times that a variable or input is switched from off
to on.
In this case, every time that "X1" is turned on, the counter, is increased by one. When the
number of counts or switches from off to on that "X1" experiences reaches 3, then "CT2" is
initialized. When, in this case, the variable "C10" is initialized, the counter is reset to zero.
After 3 counts, and "CT2" is initialized, the output, "Y10" is energized.
Counter Relay
The counter relays are used to store true/false conditions for use later by other rungs. Notice
the C10 in the example above. It has been assigned a value by another rung in the program
and is used to reset the counter above.
Set and Reset Functions
The "SET" command allows this input to energize an output, and keep it energized even if
the input is turned off.
The "SET" command also allows you to energize multiple outputs from a single input as
shown in the example above, but multiple outputs are not necessary with this function. Once
an output is energized with the "SET" command, it will remain on until it is reset.
The "RST" function will reset, or turn off the outputs or variables as shown in the example.
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In the example, when the input "X1" is turned on, the outputs: Y5-Y22 will reset to the off
position.
End
The end command is used to end all programs.
5. Results:
6. Conclusion and Discussion:
 What are the types of I/Os in PLC?

 Can we add number of inputs and outputs to a kit?
 Compare analog and digital I/Os on Kit.
8. References:

edition, 2001.
20
Process Automation
Experiment No. : 3
Verification of pneumatic applications

using PLC
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Experiment No. : 3
1. Aim: Verification of pneumatic applications using PLC.
PLC can be connected to pneumatic kit. Using air signal one will be able to operate single
and double acting cylinders using PLC logic
3. Hardware Required: Allen Bradley Micro logix 1400 series A PLC Simulation Kit,
PC, RS 232 or Ethernet cable for communication, pneumatic trainer kit with air
supply and wires,
4. Theory: Following are the different pneumatic application examples to be verified

using PLC.
Example 1 : Double acting cylinder is used to perform machining operation. Pneumatic

cylinder is advanced by pressing two push buttons simultaneously. If any one of the push
button is released, cylinder comes back to start position. Draw the pneumatic circuit, PLC
wiring diagram and ladder diagram to implement this task.
1.0 +
Assignment Table
B1 PB2
PLC PB1 11
12
PB2 12
1.1 O1 Y1 01
4 2
Y1 Y1
5 3
1
0
wiring diagram
11 12 O1
Ladder diagram
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The pushbuttons PB1 and PB2 are connected at memory address I1 and I2. I1 and I2 are
connected in series in ladder diagram to relase this AND logic function. When the push buttons
PB1 and PB2 are pressed simultaneously, the addresses I1 and I2 turn to state 1 from state 0 , as a
result power flows thorugh the coil and there will be output at coil 01. Output at the coil 01
operated the solenoid coil and cylinder moves forward to do the required operation.
If any one of PB1 and PB2 is pressed, then corresponding bit addresses turns to 0, since I1 and I2
are in series , if any of them turns to 0 state , there will not be any outout at 01 and thus solenoid
is de-energised and returns back.
Example 2 : Double acting cylinder is used to perform forward and return motion. Pneumatic
cylinder is advanced by pressing push buttons PB1. Cylinder is returned by pressing push button PB2.
Draw the pneumatic circuit, PLC wiring diagram and ladder diagram to implement this task.
When the pushbutton PB1 is pressed state of the address I1 turns to 1 and thus there will be output 01.
The output of 01 operates the solenoid Y1 and cylinder moves forward, When the cylinder reaches the
extreme forward position, and Push button PB2 is operated , the state of address I2 turns to 1 and thus
there will be output 02. The output of 02 operates the solenoid Y2 and cylinder return back to initial
position.
Example 3 : Double acting cylinder is used to perform forward and return automatically after
reaching the extreme forward position. Pneumatic cylinder is advanced by pressing push
buttons PB1. Draw the pneumatic circuit, PLC wiring diagram and ladder diagram to
implement this task.
1.0 +
S2 Assignment Table
PB1 S2
PLC PB1 11
11 13
S2 13
1.1 O1 O2 Y1 01
4 2
Y2 02
Y1 Y2 Y1 Y2
5 3
1
0
PLC wiring diagram
11 O1
1
13 O2
2
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When the pushbutton PB1 is pressed state of the address I1 turns to 1 and thus there will be output 01.
The output of 01 operates the solenoid Y1 and cylinder moves forward, When the cylinder reaches the
extreme forward position, and Limit switch S2 is operated , the state of address I3 turns to 1 and thus
there will be output 02. The output of 02 operates the solenoid Y2 and cylinder return back to initial
position.When PB1 is pressed, address I1 input state goes to 1 and there is an output at O1. Due to
output at O1, the solenoid coil Y1 is operated and cylinder moves forward. When cylinder reaches
end position , limit switch S2 is operated and as a result address I3 changes to 1 and consequently
starts the timer T1. The signal state of timer T1 changes to 1 after 20 seconds is reached. At the end of
20 seconds there will be output from Timer T1 set output O2. Coil Y2 is energised thus causing the
return motion of the cylinder.
5. Results:
6. Conclusion and discussions :
 How PLC is useful in pneumatic applications

 Which type of valve is involved in pneumatic application?
8. References:
1. Pneumatics, Festo Didactic.
2. Hydraulics, Festo Didactic
3. Bella G. Liptak,”Process Control and Optimization, Instrument Engineer’s Handbook”,

4th Edition, CRC Press. 4
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Process Automation
Experiment No. : 4
To write a program for witching the two
lamps
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Experiment No. : 4
1. Aim: To write a program for switching two lamps.
Sequence of the program can be understood. Listing the inputs and outputs is the most
important parameter in writing a PLC logic which can be used to perform while simulating a
given application.
3. Hardware: The PLC Simulator kit, Wires, PC for interfacing.
4 Program Sequence: 1. START PB Lamp 1 is ON
2. After 2 sec lamp 1 is OFF and lamp 2 is ON
3. After 2 sec lamp 2 is OFF and lamp 1 is ON
Function Input Output Address
5. Ladder Logic:
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6. Results :
7. Conclusion and discussion:
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 What is the nature of I/Os in this program?

 Can we use counter for this application?
9. References:

edition, 2001.
28
Process Automation
Experiment No. : 5
To write a program to fill the two tanks
with water
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Experiment No. : 5
1. Aim: To write a program to fill the two tanks with water.
given application.
3. Hardware : The PLC Simulator kit, Wires, PC for interfacing.
4. Program Sequence: 1. START PB to start the filling of water through main Pump.
2. When first tank is full automatically second tank starts to fill
By closing first tank valve and opening second tank valve
3. Indication for second lamp is full
4. Main Pump is OFF
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5. Ladder Logic:
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6. Results :

 Which type of timer is used for this application?
9. References:

edition, 2001.
32
Process Automation
Experiment No. : 6
To write a program for conveyor belt
application
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Experiment No. : 6
1. Aim: To write a program for conveyor belt application.
given application.
3. Hardware: The PLC Simulator kit, Wires, PC for interfacing
4. Program Sequence: 1. START PB Belt 1 is ON.
2. After 5 sec Belt 2 is ON
3. After 5 sec Belt 2 is OFF
4. After 10 sec Belt 1 is OFF
5. Belt 1 ON- lamp 1 is ON
6. Belt 2 ON- lamp 2 is ON
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5. Ladder Logic:
35
6. Results :

 What is the minimum number timer required in this program?
9. References:

edition, 2001.
36
Process Automation
Experiment No. : 7
To write a program for car parking
system at each floor of 2 storey buiding.
37
Experiment No. : 7
1. Aim: To write a program for car parking system at each floor of 2.storey building
given application.
3. Hardware: The PLC Simulator kit, Wires, PC for interfacing
4. Program Sequence: 1. START PB first car entry
2. After 30 cars floor 0 is OFF for parking
3. Floor 1 ON for parking
4. If full Floor 1 is OFF for parking
5. Floor 2 is ON for parking
6. If full Floor 2 is OFF
7. Empty place indication with green signal
8. Floor full indication red signal
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5. Ladder Logic:
39
6. Results:

 If number of cars exceeds is there any change in logic?
9. References:

edition, 2001.
40
Process Automation
Experiment No. : 8
To study DCS programming using
Function Block Diagram method
41
Experiment No. : 8
1. Aim: To study Distributed Control System (DCS) programming using Function Block
Diagram method.
The blocks in DCS Programming can be identified which are of different types having
useful functions.
3. Hardware: PC with coep virtual lab having a DCS programming simulator.
http://coep.vlab.co.in/?sub=33&brch=93&sim=440&cnt=4
4. Theory: Functional Block Diagram (FBD) Basics:
This language basically is a graphical language wherein the users are allowed to program
elements in the form of blocks. The blocks then can be wired together like electrical circuits.
It describes a function between input and output variables.
It is a graphical method of programming DCS. Functional algorithms and control strategies

for a particular plant can be implemented by FBD. The control modules are treated as unique
entity in DCS system. Each function block contains specific algorithm such as AI, AO, DI,
DO, PID and the parameters required for the algorithm. Function blocks ranges from simple
input conversion block to a complex control strategy.
Generally available Function blocks are:

 Input/ Output (I/O)
 Math
 Logical
 Timer/ Counter
 Analog Control
 Advanced control
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The description of the various parameters associated with this block:
 Definition name: This is the name by which the block is identified in the library.
 Usage name: This name can be user defined as per his/her convension.
 Parameters: These are part of the function block available for standard connection.
 Execution number: The number by which the function block is executed.
Following functions blocks are generally available in the libraries.
1. Input Output library

 Analog Input
 Analog Output
 Discrete Input
 Discrete Output
 Pulse Input
2. Math Library
 Add
 Comparator
 Divide
 Multiply
 Subtract
 Absolute value
 Integrator
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3. Logical Library
 And
 Or
 Condition
 Not
 Negative Edge Trigger
 Positive Edge Trigger
 Multiplexer
 De multiplexer
4. Timer / Counter Library

 On Delay Timer
 Off Delay Timer
 Counter
 Retentive Timer
 Timed Pulse
5. Analog Control Library

 Input Selector
 Limit
 PID
 Ratio
 Ramp
 Filter
 Scalar
 Signal Characterizer
 Signal Generator
 Signal Selector
 Splitter
Following functions blocks are generally available in the libraries.
1. Input Output library

 Analog Input
 Analog Output
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 Discrete Input
 Discrete Output
 Pulse Input
2. Math Library
 Add
 Comparator
 Divide
 Multiply
 Subtract
 Absolute value
 Integrator
3. Logical Library
 And
 Or
 Condition
 Not
 Negative Edge Trigger
 Positive Edge Trigger
 Multiplexer
 De multiplexer
4. Timer / Counter Library

 On Delay Timer
 Off Delay Timer
 Counter
 Retentive Timer
 Timed Pulse
5. Analog Control Library

 Input Selector
 Limit
 PID
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 Ratio
 Ramp
 Filter
 Scalar
 Signal Characterizer
 Signal Generator
 Signal Selector
 Splitter
6. Analog Input function Block
Analog Input (AI) Function Block accesses a single Analog measurement value and its status
on the AI channel. In manual mode, when AI block is configured, input has to be in
engineering units as well as output is indicated in engineering units on the screen. In
automatic mode, output of the block will reflect process variable value. Input to the block
could be 4-20mA or digitally communicated variable from HART based transmitter.
Analog Output function Block -
Analog output (AO) function block assigns any output value to a field devices like control
valve through a specific AO channel. In manual mode, the output parameter value can be set
manually. In automatic mode, OUT is set automatically based on set point and process
variable value in engineering units. A feedback can also be set for the output parameter.
46
Discrete (digital) Input (DI) Function Block
The Discrete Input (DI) Function blocks accesses a single digital input value with its status
between two states of the field devices. The block gives processed physical input for other
function blocks.
In automatic mode, Process variable is copied to output which can be either 0 or 1. In manual
mode, the digital input can be toggled manually and output follows the same.
Discrete (digital) Output (DO) Function Block
Digital Output block takes value from the process and writes it to specific digital output
channel. One can confirm physical output operation by configuring a hardware discrete input
to it.
In automatic mode, when the signal from process changes the output of the block which will
be connected to AO channel which in turn connects to field outputs e.g a solenoid valve,
changes.
47
Discrete (digital) Output (DO) Function Block
Digital Output block takes value from the process and writes it to specific digital output
channel. One can confirm physical output operation by configuring a hardware discrete input
to it.
In automatic mode, when the signal from process changes the output of the block which will
be connected to AO channel which in turn connects to field outputs e.g a solenoid valve,
changes.
5. Conclusion and discussion :
 What are the Function Blocks?

 Which blocks are mostly used in DCS programming?
 Name the DCS softwares amd vendors.
6. References:
1. Poppovik Bhatkar, “Distributed Computer Control for Industrial Automation”, Dekkar
2. Bela G. Liptak “Instrument engineers handbook- Process control” Chilton book company- 3rd
edition.
48
Process Automation
Experiment No. : 9
GUI development for any one
application using SCADA
49
Experiment No. : 9
1.Aim: GUI development for any one application using SCADA software.
2. What will you learn by performing this experiment
We can actually view a system with the help of SCADA software
3. Hardware: The PLC Simulator kit, Wires and PC with simulator.
4. Theory: SCADA generally refers to an industrial computer system that monitors and
controls a process. In the case of the transmission and distribution elements of electrical
utilities, SCADA will monitor substations, transformers and other electrical assets.
We can interface all three automation tools ; PLC-DCS –SCADA. Here we are verifying our
PLC logic with SCADA screens. Program sequence of PLC logic can be viewed on SCADA
screen. Following is the sequence shown for which one can write PLC program and verify it
using SCADA screen using actual plant symbols.
50
 Compare PLC-DCS-SCADA.
 Name the SCADA softwares
6. References :
1. Stuart A. Boyer, “SCADA supervisory control and data acquisition”, ISA Publication.
2. Bela G. Liptak “Instrument engineers handbook- Process control” Chilton book company- 3rd
edition.
51
Process Automation
Experiment No. : 10
Special Experiments
52
Experiment No. : 10
1. Aim: Prepare following Case studies
1. Elevator systems
2. Home Automation
3. Water Treatment
2. Requirement: Include following points in your case studies
1. Problem statement
2. List of hardware with justification
3. General Block Diagram of the system
4. Program sequence with I/O listing
5. Ladder logic
6. Operation of ladder
7. Future scope.
2. References:
1. https://globaljournals.org/GJRE_Volume15/2-Designing-of-Home-Automation.pdf
2. http://www.techpacs.com/category/Project/10-100-31/Automation--Control-of-a-3-Level-
Smart-Elevator-using-PLC-
3. http://www.indiawaterportal.org/articles/plc-scada-based-water-quality-treatment-
distribution-management-system-428-mld-pcmc-water
53

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Fourth Year Semester-VII

Our Quality Policy

Our Quality Policy

Our Motto: If it is not of quality, it is NOT RAIT!

Dr. Vijay D. Patil

To be a premier department for the study of Instrumentation Engineering through maintaining

 Creating knowledge of fundamental principles and innovative technologies through

GUI development for any one application using SCADA software.

CO1 Define automation, it’s importance, expectations from automation and

Module Week Course

To study PLC input and output symbols.

Verification of pneumatic applications using PLC.

To write a program for switching two lamps.

To write a program to fill the two tanks with water.

To write a program for Conveyor belt application.

To write a program for car parking application CO2, CO4,

GUI development for any one application using SCADA

10 W10 Special Experiments as Case Studies

Course Code Course Name Examination Scheme

1. Oral exam will be based on the entire syllabus of Process Automation.

Introduction to Programmable Logic

2. What will you learn by performing this experiment?

A programmable controller or programmable logic controller (PLC) is a device, which is

1. Input sensing devices

It is a device to interface in between the input device to CPU. The input

A typical discrete input module performs the following four task.

It is a device interfaced in between output memory to output device. The output

Name of different output module

1. Digital output module

It is generally available in four modes

This modes selects using selector switch or software command.

The term memory utilization refers to the no of memory location required to

Typical PLC memory data

Factory configured data

A programming device, or programming terminal, allows a user to enter instructions into

6. Conclusion and Discussion:

7. QUIZ / Viva Questions:

1. Gary Dunning, “Introduction to Programmable Logic controller”, Thomas Learning,

To study PLC Input Output Symbols

2. What will you learn by performing this experiment?

The three basic elements are:

Normally opened contact

Normally opened contact

example in the following:

Y2 will turn on when X1 is sensed to be on by the CPU.

Normally closed contact

Y2 will go on when X1 is sensed to be off.

when the boolean expression is satisfied. In this example:

Other Logic Elements

A timer waits a specified amount of time before it executes a command.

Set and Reset Functions

The end command is used to end all programs.

6. Conclusion and Discussion:

7. QUIZ / Viva Questions:

 What are the types of I/Os in PLC?

1. Gary Dunning, “Introduction to Programmable Logic controller”, Thomas Learning,

Verification of pneumatic applications

2. What will you learn by performing this experiment?

4. Theory: Following are the different pneumatic application examples to be verified

Example 1 : Double acting cylinder is used to perform machining operation. Pneumatic

6. Conclusion and discussions :