Siemens Internship Report

Internship Report
2011
Internship Report Of Siemens (Pakistan) Engineering Company Limited
SUBMITTED TO: Mr. Kamran Saeed Senior Executive Engineer FS Department SUBMITTED BY:
Rehan Ahamd Baig (BS-EE)

University of Management and Technology DATED: September, 16, 2011
Rehan Ahmad Baig (UMT) 1 FS Department
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PREFACE
Internship program is a fundamental part of professional studies. On one side, our theoretical knowledge helps us to understand the basic phenomena of any system and on the other side; internship provides us the opportunity to get a practical and hands on experience of our knowledge. Here we learn how to apply and materialize that abstract truth into practice in our life. In this experience students attain the opportunity to work outside their institutions and form a satisfactory relationship between their theoretical and practical work to build a new wave of confidence among them. Internship opens the door of practical knowledge to students so that they find no problem when they step in their professions. My organization was Siemens (Pakistan) Engineering Company Limited, where I worked in Field Services (FS) Department for Four weeks.
Rehan Ahmad Baig (UMT)
FS Department
Internship Report
2011
Acknowledgment
All Gratitude is to Almighty ALLAH, the most Gracious and the most Merciful who gave me the strength and will to do this work. First I would like to thank Siemens Pakistan for inviting me to spend a summer-internship and gave me the honor to work there. What makes this place so special? Not only the perfect infrastructure, the nice working atmosphere, and the large experience and knowledge gathered there, which all serves as a stable basis for further completing my degree. Also not only the company, but the members of it which helped me in every problem I had there. By this I achieved better and higher than what I was expecting. The harder it is to keep up with these high requirements on one hand, the sweeter the feeling to have them matched on the other hand. I highly appreciate the opportunity that had been given to me form leading company of the world and let me study their present work at various levels, thanks for everything I learned. Next, I would like to thank Mr. Mohammad Mohsin an Executive Engineer in BU-Field Services of Siemens Pakistan Lahore Division for teaching me the basics of the work in the department. He is one of the very competent engineers. The work, the first advices and recommendations he gave me will serve as a good basis for my future work. I thank him for supplying me with good recommendations. I have to mention nice time out and discussions with him. He was always ready to enter discussions of new topics, ideas, and results. His expertise always served me as a good example. I am very grateful to Mr. Shafqat an Executive Engineer in BU- Field Services of Siemens Pakistan Lahore Division. The atmosphere has always been a perfect source of motivation. It was great to be welcomed and introduced to him. It was pleasure to share office with him. Who was the person infecting me to spend more working hours a week. We shared not only nice discussions during work, but also nice time. I am very grateful to him who always took the time to answer my questions thoroughly sometimes even to the very depths. I have to specially mention a long-standing co-intern and friend, Hassan Zafar. Together we proved that long distance cannot be an obstacle for effective co-actions. He was always ready to enter discussions of new topics, ideas, and results. We shared the table while working. I also enjoyed sharing few evenings out with him. I thank also all others who were always willing to help, discuss some topic. Last, I want to thank my parents, without whom I would never have been able to achieve so much. I thank for their endless love, patience, and understanding. Rehan Ahmad Baig (UMT) 3 FS Department
Internship Report
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TABLE OF CONTENTS
Description Page no.
Preface.....2 Acknowledgment.3 Executive Summary.5 Introduction ....6 Company History....7 Siemens Pakistan History9 Vision Statement ..11 Mission Statement.12 Field Services.....13 AC Motors.....14 Induction Motors...16 Motor Parts.....19 AC Motor Starters .....22 Comparison Overview27 Speed Control of DC Motor...28 Speed Control of AC Motor...29 Programmable Logic Controller.....31 S7-Simatic Manager...36 Hardware configuration with S739 Programming language Ladder Diagram LD, LAD..44 Rehan Ahmad Baig (UMT) 4 FS Department
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Counter and Timer.47 Programming language FBD.49 SIMATIC S7-300..54 Types of Block...59 Types of Data.60 Programming Devices....61 Human Machine Interface.62 SCADA.63 WinCC flexible.63 Assignments..66 Experience.67 Internship Accomplishments.67 Conclusion.68
EXECUTIVE SUMMARY
This report is a comprehensive description of business activities and operational procedures of FS Department of Siemens Engineering Company limited. The report begins with the in depth study of Siemens and the people of Siemens. Siemens is a multinational company based in Germany. During my internship of Four weeks in Siemens Lahore, I was in FS Department of the company where I learned its working principles. Besides the customary learning, the moral and sound discussion of my Supervisor also made be able to understand the ethics of doing work in an organization.
FS Department
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2011
INTRODUCTION
Siemens enjoys a leading position in Pakistan in the business areas of Power, Automation and Control, Medical, Transportation, Information Technology and Industrial solutions. Siemens is the countrys No. 1 supplier of high-voltage grid stations, switchgear products and systems, power distribution and power transformers, and network consultancy. The Power Generation Group is a major player in the country. To date, the Group has added over 2,500 MW to Pakistan's power generation capacity. The Industrial Automation & Drives Technologies Group is the only major local supplier with 35 years of experience in the local manufacture of diesel generating sets to meet customer specific demands from clients on both the domestic and international markets. The success story continues with the Medical Solutions Group, which is the leading supplier of state-of-the-art equipment to major hospitals. With a workforce of over 1500 employees, Siemens is one of the most important employers in the country. Siemens is also the single largest employer of engineering graduates in the country. It follows a policy of gender equality.
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COMPANY HISTORY
Siemens AG is Europe's largest engineering conglomerate. Siemens was founded by Werner von Siemens on 12 October 1847. Based on the telegraph, his invention used a needle to point to the sequence of letters, instead of using Morse code. The company, then called TelegraphenBauanstalt von Siemens & Halske, opened its first workshop on October 12. Werner von Siemens:Made the world's first pointer telegraph Made the Electric dynamo Constructed the world's first electric railway Laying the first telegraph line linking Britain and India Built much of the modern world's infrastructure.
Siemens is today a technology giant in more than 190 countries, employing some 475,000 people worldwide. They work in the fields of
Energy Industry Healthcare
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Different Eras of Siemens:-
Beginnings and early development Company policy and international projects The second generation A period of transition The National Socialist war economy Postwar reconstruction and emergence as a global player United under a single roof Stepping into the third millennium.
[1847 1865] [1865 1890] [1890 1918] [1918 1933] [1933 1945] [1945 1966] [1966 1989] [1989 2005]
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SIEMENS PAKISTAN HISTORY

Siemens first office in Lahore [ 1922 ] Cable laying project in Karachi. [ 1932 ] The Pak Industrial & Trading Corp. Ltd. is appointed to represent SSW in Karachi. [ 1950 ] Siemens cooperates with the Pakistani government to build a production plant for manual and automatic telephone systems in Haripur. The joint venture Telephone Industries of Pakistan (TIP) is formed. [ 1952 ] Siemens Pakistan Engineering Co. founded as Private Limited Company. Switchboards production commenced. [ 1953 ] [ 1957 ]
The Pakistani government awards Siemens Karachi a contract to build a production plant for motors, transformers and switchgear. [ 1960 ] Siemens Karachi succeeds East Asiatic Company (EAC) as representative of SRW. The railway administration awards Siemens a contract to modernize the railway safety installations in West and East Pakistan. [ 1961 ] Siemens became Public Limited Company & Factory for Motors & Transformers. [ 1963 ] Siemens builds a telephone plant in Tongi and a phone cable factory in Khulna. Telephone Industries Corporation (TIC) is founded in Dacca, and Industries of Pakistan (CIP) is established in Khulna. [ 1967 ] Siemens and the Pakistani government form a joint venture named Carrier Telephone Industries (CTI), Islamabad. [ 1969 ] Introduction of Diesel Generating Sets [ 1967 ]
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Power Transformers production started~30MVA Extension in Power Transformer rating~60MVA The company begins setting up a GSM mobile radio network 412 MW Rousch Combined Cycle Power Plant Become first Value Added Reseller of SAP Export order for 132 kV substation for DEWA Dubai, UAE Launched 1.1 MVA DG Sets [ 1981 ] [ 1987 ] [ 1993 ] [ 1996 ] [ 1998 ] [ 2000 ] [ 2002 ]
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Signed agreement for first desalination plant in Karachi [ 2003 ] Launched new line of Low Voltage Switchgear System of family SIVACON 8PT. [ 2004 ] 11 Grid Stations 220kV/132kV for KESC & Acquired Carrier Telephone Industries [ 2005 ] New Jabel Airport and Dubai Sports City 132KV Grid Stations, UAE & Ghakkar 500kV Grid Station, WAPDA [ 2006 ] SAP implementation in PTCL Siemens Pakistan pioneered to manufacture 220 kV/250 MVA Power & Transformers in Pakistan [ 2007 ] New Jebel Ali Airport 132kV Grid Stations Extension Project, UAE & Inauguration of Desalination Plant for DHA Cogen Ltd [ 2008 ]
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SIEMENS VISION STATEMENT

To remain market leader and technology pace setter in the engineering and electronics industry by utilizing the high tech engineering expertise of the siemens group worldwide to maintain our strong and prominent local presence.
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Business Divisions:
Following is the overview on some of the Siemenss businesses: Power Transmission and Distribution: HV-Sub-Stations: Transformers: Switchgears: PTD Services: Industrial Solutions & Power Generation: Process Industries & Water Technologies: Engineering and Construction: Power Generation: Information Technology Services: Field Services: Siemens Building Technologies: Industriel Automation & Drives Technologies Division: Generating Sets: Healthcare Sector: Medical Solutions: OEM Onshore: Transportation Systems: Finance and Controlling: Energy Automation:
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Field Services:
(On-Call, Logistics & Maintenance Services) Master your future with Siemens Maintenance Services. If your top priorities are optimum availability and operating efficiency of your equipment, plant or industry, you should demand the best from your service partners. Siemens Maintenance Services will live up to your demands. As specialists for complete electro mechanical maintenance, we are your competent & experienced partner for all the repairs, maintenance and revamps. A partner who gives every thing to meet your priorities with reliability and from a single source. You as Siemens customer are the benchmark by which we evaluate our performance- day by day. To facilitate reliable, failsafe production facilities, innovative technologies & superb after sales support Siemens Pakistan has a dedicated Business Unit i.e. OnCall-, Logistics & Maintenance Services. Field Services use the technological & business management competencies, as well as their vast project execution & maintenance experiences enable them to provide sustainable support throughout the production phase of the industry; that help their customers to achieve their business goals more effectively . To stay competitive, it is essential to have a maintenance and modernization plan that addresses both technical and business issues. It is only when the need for performance and profitability are balanced that the desired results can be achieved. Customer equipment must be up-to-date, processes must be highly available and any improvements they make to their production facilities must deliver favorable Profits. When modifications are made - from reconstruction and expansion to site relocation - all downtime must be kept to a minimum. FS can do that: by using the unsurpassed combination of technological expertise and industryspecific experiences.
Services at a glance:
Repair, Overhauling & Maintenance of Motors & Alternators Condition Monitoring (Thermography, Vibration Analysis, NDI & Oil Analysis) Spare Parts Management Operation & Maintenance Service (Industrial and Power Plants)
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AC motors
With the almost universal adoption of AC system of distribution of electric energy for light and power, the field of application of AC motors has widened considerably during recent years. It consists of two basic parts, an outside stationary stator having coils(Armature windings) supplied with alternating current to produce a rotating magnetic field, and an inside rotor (Field windings)attached to the output shaft that is given a torque by the rotating field. Main types are: 1) Synchronous motor 2) Asynchronous motor a) Induction motor i) Single Phase motors ii) Three Phase motors
Synchronous motor: A synchronous motor is similar to an alternator with a rotating field. The stator of a synchronous motor is the same as that of the more popular induction motor. A 3-phase synchronous motor generates an electrically rotating field in the stator. Such motors are not self starting if started from a fixed frequency power source. It runs either at synchronous speed or not at all. It is not inherently self starting. It has to be run at synchronous sped by some means before it can be synchronized to the supply. A wound rotor (rotating field) which has the same number of poles as the stator, and is supplied by an external source of direct current (DC). Both brush-type and brushless exciters are used to supply the DC field current to the rotor. The rotor current establishes a north/south magnetic pole relationship in the rotor poles enabling the rotor to lock-in-step with the rotating stator flux.
Procedure for starting:

Field winding is shorted Stator voltage is reduced. The motor starts up. At steady speed, DC excitation is applied and short-circuiting of field winding is removed. Full voltage is applied at stator. Now motor can be operated at any power factor by changing the DC excitation.
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Features:
For a given frequency it runs at a constant average speed whatever the load is. It can operate over a wide range of power factors, both lagging and leading. Not self starting DC excitation is required. Can be run at ultra low speed by using high power electronic converter which generates very low frequency.
Applications:
Power factor improvement. Voltage regulation. Constant load drives.
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Induction Motor:
Most AC motors are induction motors. Induction motors are favored due to their ruggedness, simplicity (absence of brushes) and the ability to control the speed of the motor. In fact, 90% of industrial motors are induction motors. The induction motor does not have any direct supply onto the rotor; instead, a secondary current is induced in the rotor. An induction motor is sometimes called a rotating transformer because the stator (stationary part) is essentially the primary side of the transformer and the rotor (rotating part) is the secondary side. Induction motors are widely used, especially polyphase induction motors, which are frequently used in industrial drives.
Working Principle:
A conductor moving through a magnetic field will have a voltage induced into it. This is known as Electromagnetic Induction .This electrical principle is used in the operation of AC induction motors. The basic difference between an induction motor and a synchronous AC motor is that in the latter a current is supplied onto the rotor. This then creates a magnetic field. By way of contrast, the induction motor does not have any direct supply onto the rotor; instead, a secondary current is induced in the rotor. To achieve this, stator windings are arranged around the rotor so that when energized with a polyphase supply they create a rotating magnetic field pattern which sweeps past the rotor. This changing magnetic field pattern induces current in the rotor conductors. This current interacts with the rotating magnetic field created by the stator and in effect causes a rotational motion on the rotor.
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However, for these currents to be induced, the speed of the physical rotor and the speed of the rotating magnetic field in the stator must be different, or else the magnetic field will not be moving relative to the rotor conductors and no currents will be induced. This difference between the speed of the rotor and speed of the rotating magnetic field in the stator is called slip.
The rotor speed is:
Where s is the Slip is calculated using:
slip
Slip can never be zero in an induction motor. At the start it is 100%. It should be as small as possible, not more than 5%.
Construction:
Stator:
The stator is the stationary part of the motor. The stator core is cylindrical made up of several thin laminated sheets Silicon steel. These laminations are stacked together forming a
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hollow cylinder. There are slots in the inner periphery. Coils of insulated wire i.e. armature windings are inserted into slots of stator core. Each grouping of coils, together with the steel core it surrounds, form an electromagnet. Electromagnetism is the principle behind motor operation. The stator windings are connected directly to the power source.
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Rotor:
The rotor is moving part of motor. Induction motor has two types of rotors.
Squirrel-cage rotor:
The most common rotor is a squirrel-cage rotor. Core is made up of laminated sheets of Silicon steel. Slots are present on outer periphery of core and Al conductors (bars) are placed in these slots. These conductors are forming closed circuit i.e. copper rings at each end. No terminals are coming out of it. The rotor bars in squirrel-cage induction motors are not straight, but have some skew to reduce noise and harmonics.
Slip-ring rotor:
A slip ring rotor replaces the bars of the squirrel-cage rotor with copper windings that are connected to slip rings. These rings are mounted on rotor but laminated from the rotor. These can also be connected to resistors to produce a high-resistance rotor circuit, which can be beneficial in starting.
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Motor Parts
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AC motor starters
Synchronous motor:
Three basic approaches can be used to safely start a synchronous motor
1. Reducing electrical frequency:

If the stator magnetic field in a synchronous motor rotates at a low enough speed, there will be no problem for the rotor to accelerate and to lock in with the stator magnetic field. The speed of stator magnetic field can then be increased. This approach to starting synchronous motor makes a lot of sense but it does have one problem i.e. variable frequency source. Regular power systems are much regulated at 50 or 60 Hz, so we need a variable frequency voltage source. Today variable frequency drives, cycloconverters are very common in industries. In this method AC is rectified to DC and then controlled AC is obtained from this DC using inverters. This method is very easy- simply adjust the frequency to a very low value for starting, and then raise it up to the desired frequency for normal running.
2. by external prime mover:

This approach to starting a synchronous motor is to attach an external starting-motor to it and bring the synchronous motor up to full speed. The starting motor only needs to overcome the inertia of the synchronous motor without a load, so starting motor can have a much smaller rating than the synchronous motor it starts. Since most large synchronous motors have brushless excitation systems mounted on their shafts, it is often possible to use these exciters as starting motors.
3. Using Damper windings:

This is a very popular way to start a synchronous motor by employing damper windings. Damper windings are special bars laid into notches carved in the face of synchronous motors rotor and then shorted out on each end by a large shorting ring. Using damper windings motor can be started by the following procedure: Disconnect the field windings from DC source and short them out. Apply a three phase voltage to stator, and let the rotor accelerate up to near-synchronous speed. The motor should have no load on its shaft. Connect the field windings to its power source. After this is done, motor will lock into step at synchronous speed and can then be loaded.
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Induction motor:
Types of starters:
1. 2. 3. 4. 5. 6. Direct on line starter Autotransformer starter Star Delta starter Resistance starter Soft start Series reactor starter
1. Direct on line starter:

The main method of starting the AC motor is direct-on-line starting. This simply means an electro-mechanical switch is opened and closed to stop and start the motor. When an induction motor starts DOL, a very high current is drawn by the stator, in the order of 5 to 9 times the full load current. This high current can, in some motors, damage the windings; in addition, because it causes heavy line voltage drop, other appliances connected to the same line may be affected by the voltage fluctuation. To avoid such effects, several other strategies are employed for starting motors.
Disadvantages:
Electrical:

High inrush current (typically 6 x full load which can cause several problems). Necessities over sizing of installation (particularly important on generator and UPS fed supplies). Limits Expansion. Reduces service life of electrical components.
Mechanical:

Excessive applied starting torque (typically 2.5 x full load). Increases wear on drive chain components. Reduces service life of mechanical components.
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2. Autotransformer starter:
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This method uses transformer action to reduce the voltage applied to the motor and current seen by the supply. An improved torque/amp ratio is achieved and starting current is typically 3 x FLC, depending on the voltage rapping selected. Normally the voltage is applied to the motor in voltage steps through the transformer with the taps being selected through contactors. Typical tapings are 50%, 70%, followed by full voltage being applied to the motor. The major disadvantages are size and cost, and of course the mechanical snatch at switch on is not controllable and can still cause problems. Also once the tapings have been selected, it may be necessary to change them according to changes in load parameters.
Advantages:
Simple operation.
Disadvantages:

Poor controllability Bulky Very Expensive
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3. Star delta starter:
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An induction motor's windings can be connected to a 3-phase AC line in two different ways:

Wye (star in Europe), where the windings are connected from phases of the supply to the neutral; Delta (sometimes mesh in Europe), where the windings are connected between phases of the supply. A delta connection results in a higher voltage to the windings than a wye connection (the
). A star-delta starter initially connects the motor in wye, which voltage is multiplied by produces a lower starting current than delta, then switches to delta when the motor has reached a set speed.
Disadvantages of this method over DOL starting are:

Lower starting torque, which may be a serious issue with pumps or any devices with significant breakaway torque Increased complexity, as more contactors and some sort of speed switch or timers are needed Two shocks to the motor (one for the initial start and another when the motor switches from wye to delta)
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4. Resistance starter:
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This method is used with slip ring motors where the rotor poles can be accessed by way of the slip rings. Using brushes, variable power resistors are connected in series with the poles. During start-up the resistance is large and then reduced to zero at full speed. At start-up the resistance results in the stator's field strength being weakened less. As a result, the inrush current is reduced. Another important advantage is higher start-up torque. As well, the resistors generate a phase shift in the field resulting in the magnetic force acting on the rotor having a favorable angle.
5. Soft start:
The soft start is designed to apply an adjustable voltage to the motor and increase this voltage gradually over a user-selectable acceleration period. The acceleration time being dependent on the application and desired characteristics. The added advantage of this method of reduced voltage control is that the motor can also be stopped gradually by slowly reducing the output voltage to the. Soft Stop feature offers a smooth stop in many process industries such as pumps, where fast stops can result in water hammer and mechanical damage.
Advantages:

Reduced starting current Reduced starting torque Less mechanical stress Improved control of acceleration and deceleration
6. Series Reactor starter:

In series reactor starter technology, an impedance in form reactor is introduced in series with the motor terminals, which as a result reduces the motor terminal voltage resulting in the reduction on the starting current, the impedance of the reactor being the
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function of the current passing through it, it gradually reduces as the motor accelerates, and at 95 % speed the reactors are bypassed by a suitable bypass method which enables the motor run at full voltage and full speed. Air core series reactor starters or a series reactor soft starter is the most common and recommended method for fixed speed motor starting.
Comparison Overview
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Speed Control of DC Motors

Speed of DC motor can be controlled by varying Flux/Poles Armature resistance Applied voltage
DC Shunt motor:
The speed controlling techniques of DC shunt motors are as follows:
Flux control method:

The flux of DC motor can be changed by changing Shunt current. A field rheostat is used to change current. Rheostat must be small because shunt current is very small. Speed can be increased in ratio of 2:1.
Armature or Rheostat control method:

Voltage across armature is varied by inserting rheostat or resistance in series with armature. Resistance causes decrease in p.d across armature thereby decreasing armature speed. This method is useful when speed below no load is required.
Multiple voltage control:

Shunt field is connected permanently to a fixed excitation voltage. Armature voltage is varied by means of switch gears. Armature speed would be proportional to applied voltage. This method is less common.
DC Series motor:
The speed controlling techniques of DC series motors are as follows:
Flux control method:

1. Field Divertors: Series winding is shunted by a variable resistance known as shunt divertor. Flux can be varied adjusting resistance, hence speed can be varied.
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2. Armature Divertor: Divertor across armature can be used for speed lower than normal speed. Variation in speed can be controlled by varying resistance. 3. Paralleling field coils: This method is used for fan motors. Several speeds can be obtained by regulating field coils.
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Variable resistance in series:

Armature voltage can be regulated by variable resistance. Full motor current passes through resistance so loss of power is caused.
Compounded DC motors:
Changing field resistance. Changing armature voltage. Changing armature resistance
Speed Control of AC Motors

AC motors particularly, squirrel cage and wound rotor induction motors as well as synchronous motors lend themselves to well to electronic control of their speed and torque. Such a control is usually exercised by varying frequency or voltage. These AC drives can be grouped under the following categories: Static frequency changers. Variable voltage controllers. Variable current controllers. Rectifier inverter system.
Variable frequency speed control of SCIM:

These devices are basically cyclo-converters which convert incoming high line frequency directly into the desired low load frequency. The stator voltage is adjusted in proportion to the frequency in order to maintain a constant flux in the motor. A small part of reactive power required by SCIM is provided by cyclo-converters and the rest is applied by 3phase line. Hence power factor is poor which makes cyclo-converter drives feasible only small and medium power induction motors.
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Variable voltage speed control:
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These controllers vary the speed and torque of motor by varying stator voltage with the help of SCRs. The stator voltage is reduced by delaying the firing of thyristors. Power factor is low due to large lagging current hence these devices are feasible for motors rated below 15KW. Due to distortion of voltage power losses are much more.
Speed control of SCIM with rectifier inverter system:

Rectifier inverter system with a DC link is used to control speed of SCIM. The line AC voltage is first converted into DC and then controlled AC is produced. Basic Drive System: The adjustable frequency drive consists of following sections: Line voltage 3- phase AC.
Input Section - Consists of a rectifier and filter. Transforms the AC voltage into DC voltage. Control Section - The control board accepts real world inputs and performs the required operations. The tasks are performed by a microprocessor. Output Section - This section includes the base drive circuits and the inverter. The base drive signals are low level signals that tell the inverter to turn on. Motor.
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PROGRAMMABLE LOGIC CONTROLLER
Programmable Logic Controller:

Generally defined as: A Programmable Logic Controller is a user-friendly, microprocessor based, specialized computer carrying out control functions of many types and level of complexity in industrial applications. According to NEMA a PLC is: A digital electronic device using a programmable memory to store instructions and implement specific functions such as logic, sequence, counting, timing and arithmetic to control machines and processes.
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PROGRAMMABLE LOGIC SYSTEM DIAGRAM
A PLC in an Automated System is like:
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Scan Time of a PLC:
Input scan at which input terminals Are read and the input status table is updated. Program scan at which data in the input status table is applied to the user program, the program is executed and the output status table is executed. Output scan at which data associated with the output status table is transferred to output terminals.
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Mechanical Design of PLC System:

There are two common types of PLC Brick type PLC Modular or Rack type PLC
Brick Type PLC:

It is available as an integral compact package complete in power supply, processor, memory and input/output modules.
Modular or Rack Type PLC:

The modular type consists of separate modules foe power supply, processor etc. which are often mounted on a rail with in a metal cabinet.
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Parts of PLC:
A PLC basically consists of two elements: The Central Processing Unit The Input/output System
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The Input/output System:

The input/output (I/O) system is the section of a PLC to which all of the field devices are connected. The I/O system is what actually physically carries out the control commands from the program stored in the PLCs memory. The I/O system consists of two main parts: The Rack I/O Modules
The rack is an enclosure with slots in it that is connected to the CPU. I/O modules are devices with connection terminals to which the field devices are wired.
Analog I/O Modules:

An analog input interface module contains the circuitry necessary to accept the analog voltage or current signals from analog field devices. Analog input sensing devices include temperature, light, speed, pressure, and position transducer. Analog output devices include small motors, valves, analog meters and display.
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Discrete I/O Modules:
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The most common I/O interface module is the discrete type. This type of interface connects on/off type field input devices such as selector switches, push button and limit switches. Output control is limited to devices such as lights, small motors and solenoids and motor starters that require on/off switching. The central processing unit (CPU) is the part of a programmable controller that retrieves, decodes, stores, and processes information. It also executes the control program stored in the PLCs memory. In essence, the CPU is the brains of a programmable controller. The CPU has three parts: The processor The memory system The power supply
Central Processing Unit:

Parts of CPU:
Processor Unit:
The processor unit interprets the input signals and carries out the control actions, according to the program stored in its memory, communicating the decisions as action signals to the outputs.
Memory unit:
The memory system is the section of the CPU that Stores both the control program and data from the Equipment connected to the PLC.
Power Supply:
The Power Supply Unit is needed to convert the mains A.C. voltage to the low D.C. Voltage necessary for the processor and the circuits in the input and output interface modules.
A Complete PLC View
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S7-Simatic Manager
PLC Projects in Step7
A programming software for Siemens SIMATIC Step7 offers apart from the five programming Languages, defined in the standard Norm EN 61131 further programming languages. In Siemens S7 there are the following types of programs and programming languages:
Programming Languages:
Ladder Logic Sequential Function Chart (SFC) Function Block Diagram(FBD) Structural Text Programming Instruction List (IL) The languages can be mixed in any way within a PLC project. The unification and standardization of these five languages represent a compromise of historical, regional and branch-specific requirements. Provision has been made for future expansion, (such as the function block principle or the language Structured Text) plus necessary information
technology details (data type etc.) have been incorporated.

The language elements are explained with the help of a machining process involved in valve production. Two sensors are used to establish whether a work piece with correctly drilled holes is available at the machining position. If the valve to be machined is of type A or type B this is set via two selector switches the cylinder advances and presses the sleeve into the drilled hole.
Ladder diagram (LD)

Ladder diagram is a graphic programming language derived from the circuit diagram of directly wired relay controls. The ladder diagram contains contact rails to the left and the right of the diagram; these contact rails are connected to switching elements (normally open/normally closed contacts) via current paths and coil elements.
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Example of ladder diagram language
Function block diagram (FBD)

In the function block diagram, the functions and function blocks are represented Graphically and interconnected into networks. The function block diagram originates from the logic diagram for the design of electronic circuits.
Example of function block diagram language
Instruction list (IL)

Instruction list is a textual assembler-type language characterized by a simple machine model (processor with only one register). Instruction list is formulated from control instructions consisting of an operator and an operand. OR Part TypeB AND Part Present AND Drill_ok ST Sleeve in LD Part TypeA Example of instruction list language
Structured text (ST)

Structured text is high-level language based on Pascal, which consists of expressions and instructions. Instructions can be defined in the main as: Selection instructions such as IF...THEN...ELSE etc., repetition instructions such as FOR, WHILE etc. and function block invocations. Sleeve_in : = (Part_TypeA OR Part_TypeB) AND Part_Present AND Drill_ok ; Example of structured text language
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Structured text enables the formulation of numerous applications, beyond pure function technology, such as algorithmic problems (high order control algorithms etc.) and data handling (data analysis, processing of complex data structures etc.).
Sequential function chart (SFC)

The sequential function chart is a language resource for the structuring of sequenceoriented control programs. The elements of the sequential function chart are steps, transitions, alternative and parallel branching.
With regard to language philosophy, the ladder diagram, the function block diagram and instruction list have been defined in the way they are used in todays PLC technology. They are however limited to basic functions as far as their elements are concerned. This separates them essentially from the company dialects used today. The competitiveness of these languages is maintained due to the use of functions and function block.
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Hardware configuration with S7
The CPU has to know, which hardware is available Before a control with Sep7 can be projected and put into operation, the present hardware has to be configured in S7. Without the hardware configuration of the PLC and the connected blocks as for example, input- and output blocks, power supply and so on, the installation cannot be put into operation. In the hardware configuration the available hardware (power supply, CPU, blocks and profile rail) are listed in S7. After the blocks are addressed and parametered as required. Finally this configuration is loaded in the CPU. This is necessary because the CPU has to know which blocks are available, how they are addressed and parametered.
Create new project Process of the hardware configuration In order to carry out the hardware configuration a project is needed first. Either the project is available already or a new project, as in this example, is set up.
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For doing so open the menu options FILE- NEW. Alternatively you could activate the assistant for a new project or, as long as you want to open an existing project click FILE- OPEN to open and edit an existing project.
Enter project name Assign a project name to the project. In this case our project is simply called "project name". The location in which this is filed can usually stay as it is in the pre-selection. Unless you would like to store the project in a different location. In this case choose a different file. Confirm the inputs with OK.
Insert station Subsequently the new project is generated and the SIMATIC Manager is started. First according to the SIEMENS block available (S7-300, S7-400 etc.), a station has to be included. In ours we would like to include a Siemens S7-300 station. First, mark the project in the left field. Via the menu options INSERT-STATION and the corresponding choice of the stations, eg. SIMATIC 300-station, you can insert a new station.
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Open hardware configuration
2011
The station is inserted below the project node. The next step is opening the hardware configurations. Here there are a variety of methods as it is often the case. Either, like in our example via the right mouse button and the menu option OPEN or with a double click on the symbol HARDWARE on the right side of the window. Subsequently the program HW configuration is opened in a new window. First the window is empty. In the right field you will find the hardware catalogue. Here all blocks are listed in various nodes which are available in the current hardware catalogue. Like in reality first a profile rail has to be included which the blocks can be mounted onto. Only then the power supply, the CPU and input- and output blocks can be inserted. For this open the node for the station, in this example SIMATIC 300, then the node rack-300 and drag the profile rail via drag and drop in the left field of the window. Subsequently the profile rail together with the various slots is shown in the left field of the window and the single components can be inserted also via drag and drop.
Basis for the set of the units is the profile rail The single components are now dragged via drag and drop on the profile rail. On each block there is an order number. In the lower field of the hardware catalogue the corresponding order number to the marked object is indicated, eg. 6ES7 322-1BL00-0AA0. Thus a description mistake is prevented, if, eg. various blocks have the same label. This is in particular tricky for input- and output blocks.
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In our example we have inserted the power adaptor PS307 5A, the CPU 315, the input block DI 32xDC24V and the output block DO 32xDC24V/0.5A.
The components are drawn on the profile rail via drag and drop Before the configuration is loaded in the CPU the specifics of the single blocks can be read and partly be changed, for example the MPI-address of the CPU. For doing so open the corresponding block with a double click. In our example we have opened the specifics window of the CPU and can read and change the specifics in the corresponding register.
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Customizing of the properties
2011
Finally the configuration has to be loaded in the CPU. We advise you to save the configuration under STATION - SAVE before. In order to load the configurations in the CPU open the menu option PLC - DOWNLOAD and in the next window choose the CPU. Subsequently the hardware configuration is loaded in the CPU. The loading of the configuration data can also be made vice versa. The data can be loaded from the CPU in the program and after having made certain adjustments they can be loaded back again in the CPU. In order to read out the data from the CPU choose the menu option PLC - UPLOAD.
Loading into CPU
The CPU After the configuration have been saved and finished the hardware turns up in the Simatic Manager below the station. In our example we successfully inserted the CPU 315, the digital input- and output modules as well as the power supply. Only now it is possible to start with the installation of the S7 program, which can be inserted in the node below the CPU. Rehan Ahmad Baig (UMT) 43 FS Department
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Programming language Ladder Diagram LAD:

The graphic programming language ladder diagram LD has its idea from the representation of current flow charts. It is programmed with the symbols known from the current flow charts symbols, like NC contact, NO contact or coils and lamps. In networks they are connected as logic structures. By using symbol tables a ladder diagram is gaining more visual clarity, as the operands are directly indicated with names and labels, like, eg.lamp_EMERGENCYSTOPx for fact flags, LSx for light barrier, the output Q2.5 as motor_ON or similar. Example for the representation of the lamp EMERGENCYSTOP in LD without symbolic: Q4.0 Example for the representation of the lamp EMERGENCYSTOP in LD with symbolic: Lamp_EMERGENCYSTOP Example for the representation of the end switch feed in LD without symbolic: I2.0 Example for the representation of the end switch feed in LD with symbolic: Endswitch_feed The graphic programming language LD, also called in Step7 as LAD, is part of the basis software SIMATIC Step7 and is mainly used for the creation of logic operation controls. The creation of programs with the programming language LD is made with an incremental editor. The logic progress of a programmed logic operation control in the programming language LD is represented from left to right and from the top to the bottom. This is according to the program processing in Step7. The used switching symbols are determined in the standard DIN 19 239. As the programming language LD is represented according to the idea of the representation of current flows charts for connector circuits, the study of the language for those who are familiar with current flow charts is not a problem. Counters, times, jumps and other can be integrated in the ladder diagram via an additional function easily.
The logical AND-operation
Logical AND-operation An logical AND-operation consisting of two inputs I0.0 and I0.1 and an output Q0.0 is represented in the graphic programming language LD as follows. The logical OR-operation
Logical OR-operation
An logical OR-operation consisting of two inputs I0.0 and I0.1 and one output Q0.0 is represented in the graphic programming language LD as follows. The logical XOR (Exclusive-OR) operation
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XOR-operation
In order to represent a logical XOR-operation (Exclusive-OR) in the graphic programming language LD, a network must be created with NC contacts and NO contacts.
Comparison instructions in LD
In the programming language ladder diagram LD the two inputs IN1 and IN2 can be compared as follows: == IN1 is equal IN2 <> IN1 is unequal IN2 > IN1 is greater than IN2 < IN1 is less than IN2 >= IN1 is greater or equal IN2 <= IN1 is less or equal IN2 The following symbol boxes are available in LD for comparing 16 bit integers
Comparing 16 bit integer The comparing operation comparing integers (16 bit) compares two 16 bit fixed point number with each other. The two inputs IN1and IN2 are compare with each other according to which comparison is to be carried out.
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Setting an output in the programming language LD with flip-flops
Set coil Via this symbol an output is set in the programming language LD. This operation is carried out if the RLO of the previous operation has the signal state "1" . If the RLO of the previous operation has the signal state "0", the operation setting an output is not affected. Resetting an output in the programming language LD
Reset coil Via the symbol an output is reset in the programming language LD. This operation is carried out if the RLO of the previous operation has the signal state "1". If the RLO of the previous operation has the signal value "0", the operation resetting an output is not affected. A time can be indicated as operand, the time value of which is to be cleared or a counter the counting value of which is to be cleared. Flip-flops in the programming language ladder diagram LD: SR flip-flop, dominant resetting
SR-flip-flop With the operand it is indicated in LD which bit is to be set or reset (eg. Q 2.1). The operand is set via the set input "S" (requirement: signal state at "S"="1" and at "R"="0"), the operand is reset via the reset input "R" (note: if the signal state at "R"="1" and if the signal state at "S" changes subsequently from "0" to "1", the operand has the signal state "0", reset domineering). RS flip-flop, dominant setting
RS-flip-flop With the operand it is indicated which bit in LD is to be set or reset (eg. Q 2.1). The operand is set via the set input "S" , via the reset input "R" the operand is reset (note: if the signal state at "R"="1" and if the signal state at "S" subsequently changes from "0" to "1", the operand has the signal state "1" set domineering)
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Counter
Digital counters output in the form of a relay contact when a pre-assigned count value is reached.
Timer
A timer consists of an internal clock, a count value register, and an accumulator. It is used for some timing purpose.
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Counter instructions in the programming language ladder diagram LD
Counter in LD The counters in Step7 have their own reserved memory range in the CPU. In this memory range 16 bit word are reserved for each counter. The programming language ladder diagram LD supports 256 counters. S_CU, S_CD and S_CUD indicate the counter function. S_CU is an incremental counter with an input for counting incremental . S_CDis a decremental counter with an input for decremental counting and S_CUD is a counter with an input for counting incremental and one input for counting decremental. The input of a counting value is defined with a word length (16 bit) in Step7 with the maximum value 999 by using the 8421-BCD-code. The bits 12 to 15 are not important for the entry of the counter value.
Further counter instructions Counter operation CU forward counting With the operation CU the counter indicated in the operand counts forward whenever there is a positive edge in the RLO. Then the value of the counter is increased by 1 on each edge. It can be counted to 999 at the maximum. This operation can only be programmed at the right end of a logic operation chain; however, several such operations can be set. Counter operation CD backward counting With the operation CD the counter indicated in the operand counts backward whenever there is a positive edge in the RLO. The value of counter is decreased by 1 on each edge. It can be counted down from 999 at the maximum. this operation can only be programmed at the right end of a logic operation chain, however, several such operations can be set.
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Programming language Function Block Diagram

The graphical programming language FBD uses the symbols known from the Boolean algebra. The programming language FBD is part of the basic software SIMATIC Step7. In FBD complex functions in combination with logic boxes can be illustrated directly. The creation of a PLC program in FBD is made with an incremental editor. On these pages we would like to explain the following subjects: Overview about logic operations available in the programming language FBD Single bit operations in FBD with AND- and OR-logic operations, EXCLUSIVE-OR operations, SET-, RESET-Operations and edge operations Comparison operations for comparing values The meaning of EN and ENO on the boxes Conversion- and counter operations in FBD Activation of a data block and Load- and transfer function with the MOVE-Box Jump operations for branches Arithmetic functions for fixed point numbers Arithmetic functions for floating point numbers Overview about programmable control operations Master Control Relay MCR AND-, OR-logical operations in FBD The logical AND-operation in FBD The signal states of two or more operands can be queried via the logical AND-operations. The query of the operand being operated by an logical AND-operation results in a signal state, "1" or "0", in the logic operation result. If all operands of an logical AND-operation (and operand must not be negated) the signal state "1", the logic operation result RLO also holds the signal state "1".
Logical AND-operation Symbol of an logical AND-operation with two inputs in the programming language FBD: Example: Logical AND-operations of the inputs I0.1 and I0.5 and allocation to the output Q2.3 query of the signal state of the input I0.1 and storing in the RLO (the query for the signal state resulted in "1") Query of the signal state of the input I0.5 (the query of the signal state resulted in the value "1"), logic operation of the signal state with the value stored in the RLO, "1" AND "1")
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the logic operation produces a result or the signal state "1" and the storage in the RLO is made as well as the allocation to the output variable Q2.3 The logical OR-operation in FBD The signal states of two or more operands can be queried via an logical OR-operation. The query made by the OR-operated operand results in a signal state , "1" orr "0", in the logic operation result. If one or all operands of an logical OR-operation (none of the operands must be negated) have the signal state "1", the logic operation result RLO also has the signal state "1".
Logical OR-operation Symbol of an logical OR-operation with two inputs in the programming language FBD Example: Logical OR-operation of the inputs I0.1 and I0.5 and allocation to the output Q2.3 query to the signal states of the inputs I0.1 and I0.5, storing in RLO (the query of the signal state at the input I0.1 resulted in the value "1", the query to the signal state at the input I0.5 resulted in the value "0") The logical operation produces the result, or the signal state "1" and the storing in the RLO is made and the allocation to the output variables Q2.3 The logical operation AND before OR in FBD
Logical AND before OR operation With the logical operation AND-before-OR the result of a signal state query can be queried corresponding to a OR-truth table. The signal state is "1", if at least one logical AND-operation has the signal state "1" at the output. The logical operation OR before AND in FBD
Logical OR before AND operation With the logical operation OR-before-AND the result of a signal state query can be queried corresponding to an AND truth table. The signal state is "1", if all logical ORoperations hold the signal state "1" at the output.
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S, setting of an output in function block diagram FBD
2011
SET of an output Via the symbol S, set output, an output can be set. However, the output is only set if the RLO has the state "1" . The operand of the operation is set to "1" . The signal state of the operand stays "0" if the RLO has the signal state "0". R, resetting of an output in FBD
Reset of an output Via the symbol R, reset output, an ouptut is reset. However the output is only reset if the RLO has the signal state "1" . The operand of the operation is reset to "0" . The signal state of the operand stays "0" if the RLO has the signal state "0". Flipflops in the programming language function block diagram FBD:
SR flipflop , reset domineering
SR-flipflop The operand indicates which bit is set or reset (eg. Q 2.1). The operand is set via the set input "S" (provision: signal state at "S"="1" and at "R"="0"), the operand is reset via the reset input "R" (specific: if the signal state at "R"="1" and if the signal state changes at "S" from "0" to "1", then the operand has the signal stat "0", reset domineering). RS flipflop, set domineering
RS-flipflop The operand indicates which bit is to be set or reset (eg. Q 2.1). The operand is set via the set input "S" t, via the reset input "R" the operand is reset (specific: if the signal state is "R"="1" and if the signal state at "S" changes then from "0" to "1", the operand has the signal state "1", set domineering).
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Counter operations in FBD
Counter in FBD Counters are reserved memory range in the CPU. In this memory range a 16 bit word is reserved for each counter. The programming language function block diagram FBD in Step7 supports 256 counters. S_CU, S_CD and S_CUD indicate the specific counter function. S_CU is a forward counter with an input for counting forward- or incremental, S_CD is a backward counter with an input for counting backwards- or decremental and S_CUDis a counter with an input to count forward and an input to count backwards.
Criteria for Selecting a PLC:

Number of logical inputs and outputs. Memory Number of special I/O modules Scan Time Communications Software
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Advantages of PLC:
Smaller physical size than hard-wire solutions PLCs have integrated diagnostics and override functions Applications can be immediately documented Applications can be duplicated faster and less expensively Increase in flexibility Faster implementation of changes and correction Easy visualization of process running Increased visual observations Increased operation speed Increased reliability and maintainability Increased security Reprogramming capability Elimination of wiring
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SIMATIC S7-300
Features
Modular small control system for lower performance range. Performance graded range of CPUs. Extensive selection of modules. Expandable design up to 32 modules. Backplane bus integrated in modules. Can be networked with: Multipoint interface. PROFIBUS. Ethernet. Central PG\PC connection wit access to all modules. No slot restriction. Configuration & parameters setting with the help of HW config tool.
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Modules
Signal Module: (SM)
Digital input modules: Digital output modules: Analogue input modules: 24VDC,120/230VAC 24VDC,Relay Voltage, Current, Resistance, Thermocouple. Analogue output modules: Voltage, Current
Interface Module: (IM)

The IM360/IM361 and IM365 make multi-tier configurations possible. The interface modules loop the bus from one tier to another.
Dummy Module: (DM)

The DM 370 dummy modules reserve a slot for a signal module whose parameters have not been yet assigned. Dummy module can be used e.g. to reserve a slot for installation of an interface module at a later date.
Function Module: (FM)

Perform Special Functions: Counting. Positioning. Closed loop control.
Communication Processor: (CP)

Provides the following networking facilities: Point to point connections. PROFIBUS. Industrial Ethernet.
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SIMATIC S7-300
CPU Design Mode Selector:

MRES: Memory reset function (module reset) STOP: stop mode, the program is not executed RUN: program execution, read only access from PG RUN-P: program execution, read/write access from PG
Status Indicator: (LEDs)
SF
BATF = DC5V = RUN = FRCE STOP = =
Group error, internal CPU fault or fault in module with diagnostics capability Battery fault, battery empty or non existent internal 5VDC voltage indicator Flashes when CPU is starting up, then a steady light in run mode FORCE; indicates that at least one input or output is forced. Shows a steady light in stop mode Flashes slowly for a memory reset request. Flashes quickly when memory reset is being carried out. Flashes slowly when a memory reset is necessary because a memory card has been inserted.
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Memory Card:
A slot is provided for memory card. The memory card saves the memory contents in the event of power outage without need for a battery.
Battery Compartment:
There is a receptacle for a lithium battery under the cover. The battery provides backup power save the contents of RAM in the event of power outage.
MPI Connection:
Connections for a programming device or other device with MPI interface.
DP Interface:
Interface for direct connection of distributed I/Os to the CPU.
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Addressing S7-300 Modules & Configuration:

Slot numbers:
The slot numbers in the rack of an S7-300 simplify addressing in the S7- 300 environment. The position of the module in the rack determines the first address on the module.
Slot 1: Slot 2: Slot 3:
Power supply; this is the first slot by default. A power supply module is not absolutely essential. An S7-300 can also be supplied with 24V directly. Slot for the CPU. Logically reserved for an interface module for multi-tier configurations using expansion racks even if purposes. no IM is installed, it must be included for addressing
Slot 4-11:
Slot 4 is the first slot that can be used for I/O modules, communication processors or function modules. Addressing examples: A DI module in slot 4 begins with the byte address 0. The top LED of a DO module in slot 6 is called Q8.0.
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Types of Blocks:
Organization blocks (OB):
OBs form an interface between the operating system and the user program.
Function (FC) :
Functions contains partial functionality of a program. It is possible program functions so that they can be assigned parameters. Functions are also useful for program reoccurring.
System function (SFC):

They are main parameter-assignable functions integrated in the memory of the CPU, they have fixed numbers and functionality.
Function blocks (FB):

They are same as system function but the only difference is that FBs have their own memory area in fixed data blocks.
System function blocks (SFB):

They are parameter assignable blocks with fixed number and functionality.
Data blocks (DB):

These are data areas of the user program in which the user data is managed in a structural manner.
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Types of Data:
They determine the properties of data, that is how the contents of one or more associated addresses are to be represented. Mainly there are three data types: Elementary data types Complex data types User defined data types Keyword BOOL BYTE WORD DWORD CHAR S5TIME INT DINT REAL TIME DATE Length(In bits) 1 8 16 32 8 16 16 32 32 32 16
Hardware Configuration:
The modules are supplied from the factory with preset parameters. If these default settings are OK, a hardware configuration is not necessary.
A configuration is necessary:
If you want to change the preset parameters or addresses of modules (such as to enable the hardware interrupt of the module). If you want to configure communication connections. With stations that have distributed peripherals (PROFIBUS-DP). With fault-tolerant programmable logic controller.
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Set point Configuration

When you configure a system, a set point configuration is created. It contains a hardware station with the planned modules and the associated parameters. The PLC system is assembled according to the set point configuration. During commissioning, the set point configuration is downloaded to the CPU.
Actual Configuration
In an assembled system, the actual existing configuration and parameter assignment of the modules can be uploaded to the CPU. This creates a new HW station in the project.
Programming Devices: Field PG:

An industry standard programming device. The field PG is powerful and easy to use, especially for maintenance and service. It is also appropriate for programming and configuration. Features: Dimensions in note book format. 2 hours battery operation. AT-Compatible. TFT color display. Equipped with all necessary SIMATIC interface ports.
Power PG:
A portable programming device, ideal for all applications in an automation project. It is also an extremely powerful, industry standard PC. Features: High level system performance. Excellent expansion facilities. TFT color display. Highly rugged design. Equipped with all necessary SIMATIC interface ports.
Power PG Rehan Ahmad Baig (UMT) 61
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Human Machine Interface (HMI)
SIMATIC HMI, the leading Human Machine Interface solution With SIMATIC HMI, we offer a complete, integrated Human Machine Interface suite that includes best-in-class products and systems for all HMI tasks. Our systems range includes operating devices and visualization software for machine-level HMI as well as the SCADA system, which can be used for a broad range of process visualization requirements.
HMI (Human Machine Interface) The user interface in a manufacturing or process control
system. It provides a graphics-based visualization of an industrial control and monitoring system. Previously called an "MMI" (man machine interface), an HMI typically resides in an officebased Windows computer that communicates with a specialized computer in the plant such as a programmable automation controller (PAC), programmable logic controller (PLC) or distributed control system (DCS). Contrast with OI. See PAC, PLC, DCS, GUI and user interface. Human-machine interfaces (HMI) connect engineers and maintenance personnel to real-time factory information. Siemens offers a broad spectrum of both Touch Panel Units and Operator Panel Units. Available with total training & support solutions
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SCADA SCADA (supervisory control and data acquisition) industrial control systems: computer systems that monitor and control industrial, infrastructure, or facility-based processes. Software used in SCADA are Sicam and Toolbox 2 to monitor the whole system and its nodes. Supervision tools or SCADA are aimed at all industries needing to pilot or see their equipment. Situated at Level II of CIM Computer Integrated Manufacturing, the main aim of these realtime tools is the graphics representation and the management of the advanced functions of the process. Supervision systems enable a global view of the equipment in order to see their physical/functional state. Situated in the command room or at the foot of the machine itself, Supervision systems offer the possibility of transmitting and of centralizing the vision and piloting of physical equipment (sensors, motors, valves...) which are otherwise very far. The implemented interface contracts are required to communicate with command control systems (API, SNCC, special machines) and are endorsed by industrial communication protocols. Being the primary technological or I.T. means of treating the process information, Supervision systems are dedicated to the operators.
WinCC flexible:
WinCC flexible is ideal for use as the HMI software in all applications in which operator control and monitoring is required on site - whether in production and process automation. WinCC flexible is designed on a non-industry specific basis and it offers Engineering Software for SIMATIC HMI operator control and monitoring devices from the smallest Micro Panel up to PCs as well as Runtime Visualization Software for single-user solutions under Windows XP and Vista. In this connection, you can transfer projects to different HMI platforms and run them there without needing to convert the projects.
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WinCC flexible/Archives
Archiving process values and messages Overview Description Area of application Benefits Design and functions
Description Process value and message archiving using WinCC flexible/Archives is for acquiring and processing process data from an industrial plant/machine. Evaluating archived process data then gives you information about the operating status of the plant/machine in the course of the industrial process (production, machining, processing, etc.) In this context, you can document the course of the process; check the rate of utilization or quality of production; or verify repeated error status conditions. top of page Area of application Integrated in HMI devices from series 270 upwards and optional for PC-Systems under WinCC flexible Advanced top of page Benefits Early detection of danger and disturbances Avoidance of down times due to predictive diagnostics Increased product quality and productivity due to regular evaluation of archives top of page

Design and functions Trend and alarm displays To represent and evaluate archived process values, you can use a configurable trend display in your screens. A cursor line helps you to read off the values. There is also a configurable alarm display for chronologically displaying the acquired messages on the screen.
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Archiving and evaluation You can export acquired process values and messages for long-term archiving either manually or on a process-controlled basis. Depending on the length of the archiving period, you can save the process data in sequence or cyclic archives either as CSV files or in ODBC databases (e.g. Microsoft Access). In this context, the system uses all the archiving media that Windows supports. Simatic WinCC flexible is the innovative HMI software under Windows for all machine level applications in machine, series machine and plant construction. The range of operator panels extends from Micro Panels, which are designed for applications with small Simatic S7-200 controllers, to plant-wide solutions with Simatic Panel PCs or IPCs.
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Connectivity to SIMATIC S7 via PPI, MPI, PROFIBUS-DP and Industrial Ethernet, to SIMOTION and SINUMERIK plus multi-protocol drivers for controllers made by leading manufacturers and manufacturer-independent communication via OPC ensures that you always have the right connection for a wide variety of automation solutions. WinCC flexible supports PROFINET, the innovative standard for industrial communication from field level to plant management level. Time-critical inputs via direct keys or a hand wheel on the HMI devices can be performed in real time via PROFINET IO.
ASSIGNMENTS
During my internship my supervisor gave me different task to do on the SIMATIC MANAGER STEP7 and WINCC FLEXIBLE major tasks such as:
Parking control system (SIMATIC MANAGER STEP7) Traffic Signals (SIMATIC MANAGER STEP7) Fruit Juice Mixer (SIMATIC MANAGER STEP7) Home Automation (WINCC FLEXIBLE) Fluid level Indicator (WINCC FLEXIBLE) Motor Speed and direction Control System
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SIEMENS EXPERIENCE
I always wanted to work in a good multinational organization to get professional knowledge and skill. I was fortunate enough to do internship in Siemens Pakistan, Lahore where I spent Four weeks and attained a lot of experience. I joined SIEMENS Lahore on 1st of July for my internship. My department was Field Services. On the very first day of my internship, I met Mr. Muneeb and Mr. Fahad Executive Engineers in BU-Field Services of Siemens Pakistan Lahore Division, they gave me a brief introduction of company and the working at Siemens Office, Lahore. He encouraged me to learn during my stay here in Siemens that Will help me in future. My supervisor Mr. Kamran Saeed gave me a brief introduction of the department and the overall working here. He provided me few booklets/broachers related to Siemens Field Services department.
INTERNSHIP ACCOMPLISHMENTS
Thorough understanding of the company (FS department) working, structure, procedures including its management. I also recognized the mutual cooperation between the technical and the commercial people and how they interacted with each other in sales, purchases and marketing of the companys product. During my internship, I also worked with my supervisor. My supervisor taught me the professional way of dealing with a customer. If a customer wants some product, first of all we should note down the specifications of the product, and this is what I practiced myself. Then if the product is available or if there are some alterations, then we have to contact the customer to inform him about the overall availability of the product. One other good opportunity for an internee is that you can get a lot of material to study. This enables you to get the in depth knowledge of many of the Siemens products. During my internship, I studied various booklets, broachers, manuals on all the equipments and those which are used in the Automation.
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CONCLUSION
I believe working at Siemens facility was among the best technical working experiences that I have ever had in my life. I believe Siemens has a long way to go in its quest for the leading industry in terms of power innovation and the production of sound technical expertise in this country. However the work ethics practiced at Siemens were compelling evidence that their multinational company is on the rise. Names such as Mr. Shafqat, Mr. Mohammad Mohsin shall always be my guiding source. Without their strong advice, and sincere conviction I would have surely never learnt all this in Four weeks. Finally, I apologies all other unnamed people who helped me in my Internship.
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Internship Report

Internship Report Of Siemens (Pakistan) Engineering Company Limited

Rehan Ahamd Baig (BS-EE)

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

Energy Industry Healthcare

Rehan Ahmad Baig (UMT)

Different Eras of Siemens:-

Rehan Ahmad Baig (UMT)

SIEMENS PAKISTAN HISTORY

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

SIEMENS VISION STATEMENT

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

Procedure for starting:

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

The rotor speed is:

Where s is the Slip is calculated using:

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

1. Reducing electrical frequency:

2. by external prime mover:

3. Using Damper windings:

Rehan Ahmad Baig (UMT)

1. Direct on line starter:

Rehan Ahmad Baig (UMT)

Poor controllability Bulky Very Expensive

Rehan Ahmad Baig (UMT)

Disadvantages of this method over DOL starting are:

Rehan Ahmad Baig (UMT)

6. Series Reactor starter:

Rehan Ahmad Baig (UMT)

Rehan Ahmad Baig (UMT)

Speed Control of DC Motors

Flux control method:

Armature or Rheostat control method:

Multiple voltage control:

Flux control method:

Rehan Ahmad Baig (UMT)

Variable resistance in series:

Speed Control of AC Motors

Variable frequency speed control of SCIM:

Rehan Ahmad Baig (UMT)

Speed control of SCIM with rectifier inverter system:

Rehan Ahmad Baig (UMT)

PROGRAMMABLE LOGIC CONTROLLER

Programmable Logic Controller:

Rehan Ahmad Baig (UMT)

PROGRAMMABLE LOGIC SYSTEM DIAGRAM

A PLC in an Automated System is like:

Rehan Ahmad Baig (UMT)

Mechanical Design of PLC System:

Brick Type PLC:

Modular or Rack Type PLC:

Rehan Ahmad Baig (UMT)