SCADA Systems Training

This training will aid in skills transfer in areas of industrial automation; PLC programming, commissioning of Variable Frequency Drives, SCADA system configuration, sensors wiring and configuration.

Target Group

This course is suitable for all those who interact with industrial control systems in their workstations, instructors, design engineers, maintenance personnel, operators, technicians and any other persons interested in understanding these systems.

Training Objectives

Upon completion of this training, participants will be able to:

• Understand PLC components and inputs/outputs wiring.
• Understand sensors and switches configuration in connection to PLCs.
• Understand the components of a VFD.
• Perform commissioning of a VFD.
• Create a SCADA control system.
• Actuator control using a SCADA system.
• Perform VFD control using a PLC and HMI.
• Establish reasons for machine stoppages with the aid of the PLC program.

Training Content

The training will be divided into three sections as follows:

Programmable Logic Controller

• Introduction to PLC architecture
• Differences between relay-based systems and PLC-based systems
• Differences between PC-based and PLC-based systems
• Advantages of PLCs
• Logical flow concept
• Scan time information
• PLC addressing concept
• Creating new projects in various PLC software
• Force table (for forcing output various variables)
• Developing the ladder diagram in various PLC software
• Information-oriented with MPI cable adapter communication cable
• Purpose of MPI and rs232 programming cable
• Maintenance practices
• Troubleshooting actual problems
• Advanced diagnostics
• Documentation and backup of PLC programs

B.  Supervisory Control and Data Acquisition (SCADA)

Introduction to SCADA

• History of SCADA
• Network Components
• What can SCADA do?
• How SCADA Systems Work
• Where is SCADA used?
• What’s the Value of SCADA?
• An Example of a SCADA System
• Data Acquisition
• Data Communication
• Data Presentation
• Control
• Next-Generation SCADA Systems
• SCADA System Challenges

SCADA System Overview

• SCADA Architecture
• Hardware Architecture
• Software Architecture
• Communications
• Interfaces
• System components
• Remote Terminal Unit (RTU)
• Programmable Logic Controller (PLC)
• Human Machine Interface (HMI)
• Data Representation Formats
• Real-Time Operations
• Features and types of the RTU

SCADA Systems Operations and Integration

• Application Development
• SCADA System Requirements and Analysis
• Types of SCADA Networks
• SCADA Configuration
• Planning and Managing SCADA Projects
• Specifications; Alternative Strategies
• Implementation and Commissioning
• Five phases to creating a functional SCADA system
• The Design of the system architecture
• The supply and programming of the communication equipment
• The HMI graphic and alarm software programs
• The Installation of the communication equipment and the system
• The Commissioning of the system;
• Systems Integration and Testing SCADA

C. Variable Frequency Drive (VFD)

Introduction to motor drive system design

• Pros & cons of adjusting motor speed
• Identify motor/drive building blocks
• Determine operating costs (maintenance, process, space requirements)
• Technological capabilities
• Operational reliability (impacts on existing equipment)
• Application characteristics (torque, speed, process requirements)

AC Induction Motors

• Motor construction

• How does a motor produce torque?
• Speed, pole, frequency relationship
• Types of AC motors
• Motor protection
• Efficiency ratings

Motor Preventive Maintenance

• Identifying overloading
• Loose connections
• Phase/voltage unbalance
• Single phasing
• Environmental concerns
• Effects of common mode voltage on bearings & fixes
• Motor nameplate information

Drive Fundamentals & Electronics

• Converter, DC Bus, inverter
• Pulse width modulation
• Carrier & fundamental frequencies
• Torque-producing and magnetizing current
• External operator control wiring
• Analogue control

Troubleshooting Drives

• Understanding fault codes

• Clearing faults
• Symptoms & corrective action

Drive Maintenance

• Dry, clean, cool & tight
• Isolation transformer/reactors
• Operator interfaces

Proper Selection & Application for Drives

• Load matching
• Bypass considerations
• Facility operating problems
• Variable torque operations
• Fans and Pumps
• Payback/return on investment calculations

“Hands-On” Lab Exercises Include:

• Use of a scope meter
• Identifying voltage signals
• Programming basic drive parameters
• Drive control wiring
• Drive diagnostics
• Troubleshooting using the keypad