The future of Industrial automation PLC SCADA technologies

Every industrial automation PLC SCADA project starts with the familiar process of counting I/O, selecting vendors, laying out PLC chassis, and distributing requests for quotes. And finally you are commissioning a system built on general standards, repeating the same mistakes as previous systems.

The conversations also repeat during bid review or negotiation meetings when someone points out inconsistent or outdated standards. Technology is changing so fast, and the past few years have brought technical advances that have breathed new life into Industrial automation groups and started great discussions around what the future holds. There is still a lot of work to be done.

Virtualization is a great example. Early adopters saw the benefits, and news spread like wildfire. As SCADA (supervisory control and data acquisition), manufacturing execution systems, and historian capabilities increased, so did the need for processing power, and virtualization was the perfect answer. Virtualization is now commonplace in Industrial automation domain. And many are asking what is next. The next big thing is waiting to happen. Industry has become more demanding asking for virtualized controllers and solution with mobility. But they are easily feasible with existing technology. The success of our industry depends on it.

HMI/PLC SCADA industrial automation applications have already secured their place as key components for any smart factory, IT-focused applications. Humans by nature are reluctant to give up control; however, fully automated facility does not mean a complete end of human interference on the factory. Considering the huge focus in industrial automation / automated equipment and intelligent HMI/PLC SCADA software, it is important that manufacturers invest in employee training, enabling talented engineers from industrial automation domain to focus on important tasks. 

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Vocational training

Current era is of knowledge economy. Talents and skills of employees form the most critical competitive advantage for any company. 15 million job seekers enter into job market each year. On the other side companies do not get sufficiently skilled manpower. Hiring, training the right talent and retaining them with the company is huge cost. So its not possible for every employers to skill & build their talent continuously. 

Now the question arises how would the companies get trained skilled manpower for their jobs? The answer is skill training providers.

We at Sofcon India Pvt LTD has aligned our training programs on Industrial automation, PLC SCADA, Embedded systems AVR Microcontrollers HVAC control, HVAC Design and drafting, VLSI, Building automation, Electronics surveillance, Hydraulics & Pneumatics trainings with industry requirements. Our training programs are also aligned with QPNOS (Qualification pack National occupation standards). QPNOS are set of standards set by NSDC for variety of job roles for different industries.

Where there is high attrition rate, employers are unwilling to pay for training for the candidates. Although they are willing to re-train and pay for already trained candidates. Now it becomes necessary for fresher entering into job-market to acquire the necessary skills mandatory for entry into a job role.

Engineers trained on PLC SCADA systems are given practical experience on hardware & software design. They know about different types of sensors and final control elements. These engineers are suitable for project engineer, design engineer & commissioning engineers job. A week time on job is enough for them to do justice to their assigned job role. Consumption of electronics tabs, mobile, pcs have increased many-fold which has pushed promising technology job opportunities for embedded system engineers, AVR/ARM Microcontroller training, VLSI, System verilog, VHDL trained engineers.

Industry is showing signs of recovery. India is going to be world leader in automotives. Hydraulics training, pneumatics training plays very important role in filling skill gaps of automotive and other industries. We are fastest developing country in the world. Our infrastructure sector is going to have huge growth potential. HVAC control & HVAC Design & drafting are key skills needed for mechanical engineers wanting to enter this segment.

Be it designing of air conditioning system, ducting, load calculation, HVAC control system, Building automation system. Learning of engineer’s undergone practical training is much faster and they can be assigned independent project design, project execution jobs.

Working of SCADA System In Steel Industries

SCADA means  Supervisory Control and Data Acquisition. SCADA is a system which is used to monitoring the running process, monitoring the parameters as well as control the output and collection of data. Generally SCADA used in the control system in any of the plant where we monitor and control.

It consist of three types of station:- 

1.      Operation Station

2.      Engineering Station

3.      Server Station

Ø  In the Operation Station the operator monitors the working process and online parameters.

Ø  In the Engineering Station the specialists of SCADA develop the SCADA, modifying the SCADA requirement if required.

Ø  In the Server Station the SCADA does not work as an Operation Station & Engineering Station it just only stored in server data when in any main station.

Now a days the SCADA used in world wide industries e.g. Steel, food, oil, package cement etc. In the steel plant we does not only use SCADA but we use all Automation equipment like Electrical Motor, Instrumentation network. SCADA is depend on the programming of PLC.

The major function of SCADA in Steel plant is to Supervision, runtime controlling the field device & collect the data. Due to Industrial standards and their characteristics which very important for plant operation point of view, the SCADA system has accepted by major of the plant.

Why SCADA used in Steel Plant:-

In the Steel plant for Monitoring & controlling function SCADA is the best system, some features of SCADA system which is best in industries are given below:-

1)      SCADA system is fully computer based software which is used to control Electrical Equipment, collect & store very large amount of data.

2)      SCADA system allows to plant engineer to interact real time process data from level 0 equipment, field sensors etc.

3)      The input output terminal unit which is working in remote area is the main source of process data this create online image of the system.

Advantages of SCADA system:-

1)      Easy to under stood the operation of plant, Easy to developed the plant design in SCADA system.

2)      SCADA is reliable and robust system that’s why it is used in critical industrial process environment where reliability and performance is priority. In well established framework specific development is performed by SCADA system that enhance reliability and robustness of the system.

SCADA is just the tip of the ice bug. Other tools & skills are required to fully Automate the industry’s control processor like Motor, Drive, Process Instruments, DCS, Penal Design etc. For more information:-

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Industrial automation HMI/PLC SCADA software and Pharmaceutical companies

There has always been serious emphasis in reliable data in pharmaceutical manufacturing. In simple terms, pharmaceutical manufacturers should follow instructions and document actions correctly, so that if any deviation occurs in the product, the company can investigate it and put measures in place so that the same error does not happen again. This guarantees the repeatability and safety of the product being manufactured and protects the brand.

Data integrity refers to the completeness, consistency and accuracy of data, which needs to be attributable and legible. More importantly, drugs approved on basis of inaccurate data could pose a threat to patients’ lives. For all these reasons data integrity is at the heart of the pharmaceutical ecosystem.

Use of reliable HMI/PLC SCADA software

The pharmaceutical industry has been slowly transitioning from manual paper records to industrial automation PLC SCADA HMI based electronic records. Batch records are in electronic form today, but other systems, including production processes, documentation and sampling, are yet to be digitalised. Although paper records can work well for some companies but they leave scope for human error and data manipulation than electronic records.

The true benefits of digital records is realised when companies use reliable industrial automation HMI/PLC SCADA software that automatically records the actions at each stage. The PLC SCADA software also makes data manipulation impossible. Another advantage of using SCADA HMI software for electronic records is that there are no more gaps in the records, which in turn improves data accuracy/Integrity. HMI/PLC SCADA software can automatically log any critical event and allows users to set alarms or notifications whenever pre-defined values exceed set parameters. This ensures that any deviation in the industrial automation process is identified in real-time.

The individual login ensures data integrity

To ensure precise data integrity individual logins are assigned. The general practice used is to assign username and password to each operator/individual. With individual user login enabled, the system can record any action or change made by an operator, thus offering a clear picture of the overall industrial automation process.

Data safety Data safety is of critical importance for pharmaceutical companies. How does a manufacturer ensure that its production data is safe and cannot be manipulated? By using reliable HMI PLC SCADA Software, companies can help eliminate this issue. When exporting archives to an external database, the software uses its internal mechanisms to check whether the data has been correctly and completely transferred. The data is never lost or corrupted. To ensure data safety, the PLC SCADA software stores critical data such as audit reports, alarm and event. By integrating Industrial automation HMI/PLC SCADA software with ERP system, pharmaceutical manufacturers can achieve savings; reduce energy consumption and raw material wastage, eliminate unplanned downtime by applying predictive maintenance. Manufacturers can have optimum utilization of manpower by freeing the staff used for recording data manually and employing their skills elsewhere in the business.

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Industrial automation technologies in coming days

Industrial automation demands continuous innovation. Right from invention of PLC SCADA in late sixties to the introduction of the robots in industry today, technological developments are continuously shaping the industrial automation ecosystem.

 
Internet of Things

A new buzzword, the Internet of Things is a core component of the connected factory. The sensors used to link Industrial automation technologies together are not new, but the decreasing size and cost of sensors has increased technology penetration across a growing range of devices. The sensors gather information on level, flow, position, sound, vibration, temperature and much more and this data is fed to PLC SCADA and used to control processes, alert the plant manager of problems and correct issues – even before a plant manager is aware of the problem.

 
Computing power of Industrial automation

Industrial computers are the heart of industrial automation PLC SCADA systems. Introduction of small, powerful microprocessors, which can precisely control machines by interpreting signals from other equipment. Smaller, faster sensors linked to increasingly powerful computers are the key to the smart factory. Industrial automation systems with high computing power can capture, process and analyse the big data from the factory floor and use it to improve productivity, avoid downtime through predictive maintenance, improve equipment use, optimise energy use, enable remote access and manage cyber security. 

 
Software Power

The global industrial automation PLC SCADA software market is growing very fast, part of which has been attributed to the integration of software with design and enterprise features, improving functionality. One factor limiting the market and expected to continue to do so is system security. This is done using a set of standardised requests – APIs. These specify how components should interact and make it easier to develop programs. APIs are becoming a more common service or product. Manufacturing involves a range of tasks with multiple types of requirements. Businesses can now build APIs to accelerate new service developments, improve efficiency and cut costs. 

 
Wearable technology

Wearable tech in consumer markets is rapidly growing popularity; from fitness trackers to smart watches, wearable gadgets are everywhere. These devices can integrate real time data and information without hassle. Coming day could see an increasing number of wearable technologies in industrial environments. It will have multiple benefits. Operators can have access to greater real time data for better control.

In an increasingly automated environment, wearable tech could be a way to improve the collaboration between humans and robots. There will be improvements in health and safety also through this technology; Helmets and watches containing sensors in an Industrial automation environment linked to supervisors will generate alerts and alarms about the hazards and dangerous situation of the job in hand.

2017 is already set to be an exciting year in which developments in industrial automation will drive us closer and closer to the smart factory and smart Industry. 

 

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Btech jobs For All Branches but Did You Learn Something About Engineering

Sofcon India Pvt Ltd (Industrial Automation Engineering Training Institute, Building Automation Engineering Training Centre and Cadd Centre) is group of Companies Since 1995. Sofcon India Pvt Ltd is  NSDC (Ministry of Finance) affiliated & Funded company.

Our Mission:- 2020: 100,000 Placemnt

Industrial and Building Automation Courses Jobs Roles And Eligibility

Industrial Automation Engineer: - An Automation Engineer have to work on live projects, the importance of critical thinking and decision making are essential for them, the system should be checked thoroughly at each level for achieving the required output as per the company norms. To do the required work, Individual must possess following abilities:-

1. Inspection of process control and automation systems
2. Carrying breakdown management
3. System startup assistance
4. Automation and control system design
5. Programming, simulating and testing the system
6. PLC Programming
7. Maintaining the documentation
8. Requirements gathering
9. Coordinating with Sourcing department for system trials
10. Procure and installing new system
11. Effective communication
12. Identifying and reporting the risks identified
13. Creating and sustaining a Safe, clean and environment friendly work place

The minimum qualification for this job is B. Tech. / B.E. in respective Electrical/ Mechanical/ Electronics/ Instrumentation/ Chemical/ Industrial Engineering branches. The individual should be active and ready to work for hours on the industrial environments. Excellent communication skills and proper dressing code is also required for this job, individual have to maintain proper gesture and postures during working hours.

Depending upon the installed equipments in the plant, individual have to know the complete work flow of the system as well as complete understanding of the components implemented. There are different types of PLC's used in industries as per the requirement such as Allen Bradley, Modicon, Siemens, Mitsubishi, GE Fanuc, Omron, Toshiba etc. The Automation engineers have to deal with PLC's accordingly and has to control the process flow as per the norms.

Overall efficiency of the system is completely based on the automated systems implemented in the plant; an automation engineer is responsible for the complete process flow of the overall system therefore, he should posses' deep understanding and maintains quality of the products with higher efficiency using the installed system within given time constraints. An automation engineer works as the backbone of any automated industry and fulfill the gap between industry requirement and control flow of machinery.

Job Description of Building Automation Engineer: - Building automation engineers are responsible for all the integrated automated systems on a particular site. He is the one who have to supervise the installation and maintenance of complete automation systems. It includes CCTV surveillance systems, fire alarms systems, HVAC and Access control systems such as biometrics, smart cards, automated door locks etc.

Automation is required in every sector in today's developing world, need of automation for highly secure and controlled accessibility is required in day to day life. When the output required is highly accurate with negligible errors automated machinery have to be used, such as access controllers used in Metro's, Fire alarm systems used in highly sensible sites, CCTV surveillance systems in high security regions, and HVAC's for control rooms and integrated systems. Building automation engineer is the one who is responsible for designing, assembling, installing, testing and commissioning of the overall systems integrated in automated buildings. He has to integrate all the systems and create proper communication between all the systems which can be controlled and monitored from a single panel.

The Job Role of Building Automation Engineers Are:-
1.Understanding the need of automation systems required by site survey
2.Planning the best possible system as per the requirements
3.Assist and suggest the customers about latest building automation technologies
4.Providing cost estimates to the customer as per the company norms
5.Taking approval for the systems to be installed in the building
6.Supervising and installing the systems
7.Designing and wiring the systems
8.Integrating the systems
9.Creating communication between the controllers
10.Checking the system parameters
11. Testing and repairing automated systems
12.Preparing detailed documentation
13.Explaining the customers about the installed technologies

The latest technologies used in building automation systems are controlled embedded gateways and servers, bidirectional wireless networking, IP enabled controllers, BACnet, LON and Central building management systems.

The minimum qualification required for this job is B.E. / B. Tech. in Electrical/ Mechanical/ Electronics/ Instrumentation/ Industrial engineering. As the need of automated and controlled devices in the building management systems increases rapidly, it tends to create and offer new jobs with this profile. Aspirants seeking future in this field have to be dedicated and ready to learn new technologies emerging everyday and making them self updated. They should prepare and ready to accept new challenges as per the requirements and deliver the work within given time constraints by continuous work.

Job Description of Embedded System Engineer: - Embedded system engineers are responsible for the overall working of the system on chip as per the requirements. He is the one who is responsible for designing the system on chip level by simulating, Testing and implementing it on the board. An application specific IC's are widely used integrated chips in today's electronics industry, Updated and implemented on daily basis using new and better technologies. The major job roles of an embedded system engineer are:-

1.Designing and Implementing embedded devices as per the requirements
2.Testing and debugging the programming codes
3.Integrating, validating and updating new products as per their applications
4.Programming in C, C++ and embedded systems
5.Troubleshooting and testing embedded systems
6.Monitoring and modifying Real time operating systems
7.Excellent communication skills
8.Maintaining records
9.Preparing fault reports

Embedded system engineers must be capable to work for hours on computers for programming, simulating and designing new products as per the requirements. The minimum qualification for this job is B.E. / B. Tech. in Electronics/Telecommunication/ Communication /Electrical and Electronics engineering streams. Those who are interested in VLSI stream and chip level designing can choose their career to grow as an embedded system engineer.

About CADD Centre: - It stands for Computer Aided Design and drafting, it is software used as a tool to create designing and drafting of engineering components and systems. It is used to increase the quality, efficiency and overall productivity of the systems by the creation and modifications of the installed systems as per the requirements given by the firm. CAD software can design 2D and 3D curves and figures with detailed specifications for better understanding and implementation.

CADD Centers provide world class training since last 26 years heaving branches across the globe, head quartered at Chennai. With over 520 franchise outlets across Bahrain, Bangladesh, Bhutan, India, Dubai, Malaysia, Maldives, Nigeria, Oman, Qatar, Sharjah and Sri Lanka. In last 26 years CADD centre trained over 1 Million engineers and professionals trained and placed in over 20 countries.

CADD center offers over 100 courses for students and working professionals of Mechanical/ Electrical and Electronics/ Civil/ Architecture and project management aspirants.
The main course comprises of:-

1.Mechanical CADD:- It includes Solid Works, Creo, Ansys, NX CAD, NX NASTRAN, NX CAM
2.Electrical CADD:- It includes Auto CAD Electrical
3.Architectural Design:- It includes 3ds Max, Microstation, Revit Architechture
4.Building Design:- It consist of AutoCAD civil 3D, STAAD.Pro, ANSYS Civil,
5.Structural Design:- It consist of Prosteel, RCC Det