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PLC and SCADA TRAINING SYSTEM

Order Code: 21224905.1

Category: General Lab Equipment II

10.1 PLC & SCADA TRAINING SYSTEM 10.1.1 System description and requirement. 10.1.2 The proposed PLC & SCADA Training System shall designed to focus on pratical hands-on training on...



SPECIFICATION

10.1 PLC & SCADA TRAINING SYSTEM
10.1.1 System description and requirement.
10.1.2 The proposed PLC & SCADA Training System shall designed to focus on pratical hands-on training on industrial standard system as follow:
a) PLC control system,
b) SCADA system,
c) Pneumatic system,
d) Sensors
e) Networking.
10.1.3 The proposed training shall be able to upgrade with latest IR4.0 technologies features
a) Internet-Of-Things (IoT)
,b) Augmented Reality (AR),
c) Big Data
d) Cyber Security.
10.1.4 The proposed training system shall be a table top unit, standalone, compact, self-contained and can be integrated to form a bigger system.
10.1.5 The training system learning syllabus shall apply D.I.Y (DO- It-YOURSELF) concept, allow student to perform following practical hands-on exercise
a) Hardware and sensor installation
b) Wiring work
c) Control system hardware configuration
d) Control system software configuration
e) SCADA system configuration
f) Process automation plant commissioning and testing
g) Process control tuning
h) Process and control optimizaton
10.1.6 The proposed training system shall be comprised of the following modules. These equipment modules shall be able to operate as standalone unit or integrated to a smart process production manufacturing plant.

a) Conveyor system module. The conveyor system shall be installed with proximity sensor and pneumatic actuator to control the specimen filling process.

b) Filling system and level process control module. The proposed filling system and level process control module shall be designed to perform the bottling filling process and level PID process control.

c) Temperature process control module. The proposed training system shall designed with temperature process control module.

d) Control System and SCADA System. The proposed PLC control system shall meet industrial standard and widely used in the Malaysia industry. The proposed PLC and SCADA system shall be easily upgraded with latest IR4.0 technology & Internet-Of-Things (IoT).
10.1.7 The proposed system shall be mounted on the structure with adjustable height castor wheels for easy re-allocation. The mobile strucuture shall be made of aluminium profile or stainless steel material.
10.2 The system shall meet the following technical specification:
10.2.1 Overall size equipment : approx. 1,200 x 500 x 600 mm (LWH)
10.2.2 Overall size equipment with the mounting mobile strucutre : approx. 1,200 x 500 x 1,300 mm (LWH)
10.2.3 Conveyor system
a) Wire type and power : DC 3-wire type 12-24VDC
b) Sensing side diameter : M12
c) Sensing distance : 4mm
d) Installation : Non-shield(non-flush)
e) Standard sensing target : 12×12×1mm(iron)
f) Response frequency : 500Hz
g) Current specification : Current consumption: Max. 10MA
h) Control output : PNP Normally Open
i) Material : Brass(nickel plated)
j) Protection structure : IP67
k) Hysteresis(distance) : Max. 10% of sensing distance
l) Residual voltage : Max. 1.5V
10.2.3.3 Pneumatic Actuator:
a) Type : Single acting
b) Operating pressure : 1-10 bar
c) Temperature range : -30°C to +80°C
d) Medium : Filtered, oil-free and dried compressed air according to ISO 8573-1:2010, Class 7:2:4, instrument air, free of aggressive additives. Alternatively the pressure dew point must be at least 10°C below lowest occurring ambient temperature.
e) Cylinder tube : Stainless steel
f) End caps : Al (anodized)
g) Piston rod : Stainless steel
h) Seals : PU & NB
10.2.3.4 Conveyor motor
a) Type : DC motor
b) Power supply : 24VDC
c) Speed : with gear box, shall be controlled by manually, PLC and monitored by SCADA system
d) Connectivity : connected to PLC control system, and SCADA system
10.2.4 Filing system and level process control module
10.2.4.1 Level control Tank
a) Material : Glass and stainless steel
b) Size : approx. 3L
c) Connection : clamp connected for easy installed and dismantling work
d) Features : Installed with two (2) solenoid valves at the outlet of the tank
10.2.4.2 Level transmitter
a) Measurement range : approx. 0 ~ 500 mmH2O
b) Signal : 4 ~ 30 mA
c) Power Supply : 24VDC
d) Features : can be connected to PLC control system, SCADA system and IoT system (when the system connected to IoT)
10.2.4.3 Process Control features
a) P, PI, PID level process control
b) Level Process control PID tuning
c) Level feedback PID tuning optimization using different type of tuning methods, i.e. Ziegel Nichols, Cohan Coon and IMC.
10.2.5 Temperature process control module
10.2.5.1 Preheat Hot Water Tank
a) Material : Stainless Steel
b) Size : approx. 15L
c) Tubing connection: clamp connected for easy installed and dismantling work
d) Installed with electrical heater
e) Installed with temperature sensor (RTD, PT100)
f) Installed with level sensor
g) Installed with hot water pump to recycle the hot water to heat exchanger
h) Integrated with safety interlock to protect the equipment from being ovewrheated and dry run
10.2.5.2 Water storage tank
a) Material : Stainless Steel
b) Size : approx. 12L
c) Tubing Connection: clamp connected for easy installed and dismantling work
d) Installed with electrical water pump
e) Installed with temperature sensor (RTD, PT100)
f) Installed with level sensor
g) Integrated with safety interlock to protect the equipment from being dry run
10.2.5.3 Heat Exchanger:
The heat exhanger shall be installed to process the heating process before the process medium feed into the level control process module.
10.2.5.4 Process Control features
a) P, PI, PID temperature process control
b) Temperature ON/OFF control
c) Level ON/OFF control
d) Temperature Process control PID tuning
e) Temperature feedback PID tuning optimization using different type of tuning methods, i.e. Ziegel Nichols, Cohan Coon and IMC.
10.2.6 Control System and SCADA System
10.2.6.1 Compact CPU
a) Power supply: AC 85-264 VAC at 47-63 Hz
b) AC/DC/relay, onboard I/O: 8 DI 24 VDC; 6 DO relay 2 A; 2 AI 0-10 V DC
c) Program/data memory 75 KB
d) Total I/O channels for the whole system is 12xDI, 6xDO, 2xAI and 2xAO
10.2.6.2 Digital I/O module
a) Digital input 4xDI
b) 24 VDC
c) 200 kHz
d) Sourcing input
10.2.6.3 Analog I/O module
c) 0-20 mA/4-20 mA, 13-bit resolution
b) +/-10 V, 14-bit resolution or
a) 2 x Analog output (AO)
10.2.6.4 Power Supply (24V encoder supply) : 24 V 20.4 to 28.8V
10.2.6.5 Work memory : integrated 75 kbyte
10.2.6.6 CPU-blocks
a) Number of blocks (total) DBs, FCs, FBs, counters and timers.
b)The maximum number of addressable blocks ranges from 1 to 65535
c) There is no restriction, the entire working memory can be used
10.2.6.7 Hardware configuration, number of modules per system
a) max. 3 comm. modules
b) 1 signal board
c) 2 signal modules
10.2.6.8 Interface :
a) PROFINET
b) RJ 45 (Ethernet)
10.2.6.9 Protocols :
a) PROFINET IO Controller
b) PROFINET IO Device
c) Web server
10.2.6.10 Protocols (Ethernet) :
a) TCP/IP
b) SNMP
c) DCP
d) LLDP
 
10.3 Training and learning objectives
The proposed training system shall able to deliver the following
10.3.1 Introduction to computer and programming language
a) Arrays
b) Strings
10.3.2 Functions and structures
a) Structures
b) File Processing
10.3.3 Introduction to PLC mircocontroller programming
a) Basic PLC microcontroller programming, Ladder logic diagram (LLD)
b) Basic PLC microcontroller programming, Function block
c) Basic PLC microcontroller programming, Statement list
d) Timer and counter
10.3.4 Standard PLC microcontroller i/o interface
a) LED and switching.
b) LCD output
c) Interface operation and application
10.3.5 PLC microcontroller operation and application
a) PWM and motor
b) Conveyor belt application
c) Pump speed control for level process control
d Pump speed control for temperature process control
10.3.6 Introduction to process control
a) Open loop system
b) Closed loop system
c) Process control application: Level PID control, temperature PID control
10.3.7 PID controller system
a) Temperature control system (P)
b) Temperature control system (PI)
c) Temperature control system (PID)
d) Level control system (P)
e) Level control system (PI)
f) Level control system (PID)
10.3.8 Ziegler-Nichols for PID controller
a) Ziegler Nichols water level
b) Ziegler Nichols water temperature
c) Ziegler Nichols applications
10.3.9 Ziegler-Nichols for PID controller
a) Modular servo motor 1
b) Modular servo motor 2
10.3.10 PLC as controller and application
a) Standard I/O and ladder diagram
b) Timer and counter
c) PLC applications
10.3.11 PLC with pnuematics
a) Integration PLC with pneumatic system
b) Integration PLC with electro-pneumatic system
10.3.12 Introduction to SCADA, RTU/PLC
a) Communication Architecture
b) SCADA System Hardware
c) SCADA System Software
d) Process Control for Study Temperature and Level
10.3.13 Communication Protocol of monitoring system
a) TCP/IP protocol
b) LAN protocol
c) WIFI protocol
10.3.14 Communication with SCADA system
a) LAN/WAN Communication for SCADA system
b) WIFI Communication for SCADA system
c) Motor Control
10.3.15 Introduction to Human Machine Interface (HMI)
a) Ergonomic Factor
b) HMI organization
c) HMI screen design
d) HMI Simulation lab execise
10.3.16 Introduction to Human Machine Interface (HMI)
Introduction to Human Machine Interface (HMI)
Introduction to Human Machine Interface (HMI)
Introduction to Human Machine Interface (HMI)
 

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