Siemens PLC & Automation Report

Siemens Limited.
Infium Digispace
Salt Lake, Sector V
Kolkata-700091
SONY SENGUPTA
2/2/2014
Industrial Training Report
PLC & Automation

Acknowledgement: -
I, Sony Sengupta pursuing B.TECH in Electronics and Communication
Engineering in MCKV Institute of Engineering, Liluah, would like to thank
the Department of Electrical and Automation, SIEMENS LTD, Kolkata, for
permitting me to undergo an industrial training from January 2nd
,2014 to Jan
31st
,2014.
My learning experience, my understanding of the process of information and
technology, my easy access to the projects and my innumerable questions being
answered and explained to, has all been possible because of the cooperation and
encouragement of all the coordinators and engineers in the Electrical and
Automation Department of Siemens India Ltd.
I express my deep gratitude to
Mr. Aviijit Maitra (Senior Projects Manager)
Mr .Debasis Mukherjee
Mr .Moinak Ghosh
Mr .Amit Das
Mr .Anupam Mazumdar
Mr .Sukhendu Das
Mr. Dipen Mondal.
for sharing their valuable knowledge and guiding me throughout to complete
my task effectively.
I also express my sincere thanks to HR Department Manager, Mrs. Barnali
Chatterjee who inducted me into the training system.
Regards
Sony Sengupta
Electronics and Communication Engg
MCKV Institute of Engineering

Undergraduate training Report
Student’s Name: Sony Sengupta
Branch: Electronics and communication
Year: 2nd
Semester: 4th
Title of the Project: PLC & Automation
Commencement Date: 2nd
January 2014
Completion Date: 31st
January 2014
Name of Company/Organisation: Siemens Ltd.
Student’s Signature: ____________________________________
Date:- 3rd
February 2014
I certify that Sony Sengupta has satisfactorily completed the Internship and
worked on the project referred to above. Her conduct as an intern has been
satisfactory in all respects.
(Signature of Supervisor)
Supervisor’s Name: Mr. Abhijit Maitra
Designation: Senior Manager-Projects
Company/Organisation: Siemens Ltd. Company/Organization Seal

Company Overview
Steel Making
Steelmaking automation
Basic Idea of PLC & AUTOMATION
I/O List and associated Projects
HMI(Human Machine Interface) & projects
Conclusion

INTRODUCTION:-
SIEMENS IN INDIA
The Siemens Group in India has emerged as a leading investor, innovator and
implementer of leading-age technology enabled solutions operating in the core
business segments of industry, Energy and Healthcare. The Group’s business is
represented by various companies that span across these various segments.
Siemens brings to India state-of-the-art-technology that adds value to customers
through technology that adds value to customers through a combination of
multiple high end technologies for complete solutions.Today, Siemens with its
world-class solutions, play a key role in India’s quest for developing modern
infrastructure.
SIEMENS BUSINESS SEGMENT
INDUSTRY AUTOMATION
The range of innovative products, systems and solutions for the distinctive
requirements of clients is a varied and diverse as the industry and trade itself.
The spectrum of offerings at industry automation ranges from standard products
to system solutions for energy and automation technologies used in
manufacturing and process industries. As the leading provider industry
software, the division optimizes entire value-added change for manufacturing
companies-for product design and development, to productions, sales and
services.
DRIVE TECHNOLOGIES
Siemens drive technologies has been enhancing customer productivity and
efficiency in industries ranging from aerospace, automobiles, oil and gases to
plastics, packaging, logistics and material handling. The division offers
complete electrical and mechanical technologies and components including
standard and large drives applications covering the entire drive train.

PRODUCT PORTFOLIO
The Siemens Industry Solutions Division presents its industry-specific product
families, which combine plant technology concepts with IT applications and
comprehensive services for the operational phase into perfectly coordinated
complete packages. Our integrated plant solutions based on selected and proven
standards offer customers plug produce convenience for added operating
reliability and investment security.
Areas of Expertise:
Metals and Mining (MT)
Iron and steel making
Rolling mills
Processing lines
Continuous and discontinuous mining
Mineral beneficiation
Raw material and coal handling plant
Water technologies (WT)
High purity water systems
Process water treatment
Water disinfection technologies
Waste water treatment and recycle technologies
Industrial technologies (IN)
Cement
Paper and pulp
Airports
Marine

Cross industries
Non-ferrous metals
On-call logistics and maintenance
Building technologies (BT)
Siemens Building Technologies specializes in meeting the growing demand for
increased personal
Safety and more secure public and private infrastructure by electronics security
and building automation systems. A market leader providing solutions for
“Intelligent Buildings”, the division offers a range of products and services for
security, comfort and efficiency in high-end buildings, and covers the entire
chain of offerings from engineering to services.
Mobility (mob)
A pioneer in railways signalling systems in India, Siemens offers products and
solutions in railways signalling and safety systems, traffic control and
automation, electrification, traction equipment for locomotives and multiple unit
system and mass transit vehicles. The product palette also includes rolling
stocks and auxiliary inverters for air-conditioned passenger’s coaches. Fully
equipped and backed by trained staff, turnkey projects are undertaken for urban
transportation, mass rapid transport projects, traction substations overhead
centenary and long distance transmission lines.
Portfolio includes:
Railways automation
rail electrification
turnkey systems
metros
Trains and locomotives
Light rail vehicles
Multiple units

Service, maintenance and support for rail systems
Energy sectors
Siemens consolidates its innovative offerings in Energy Sectors by combining
its full range expertise in areas of Power Generation (PG) And Power
Transmission & distribution (PTD). Utilizing the most advanced plant
diagnostics and systems technologies, Siemens provides comprehensive
services for complete power plants and rotating machines such as gas and steam
turbines, generators and compressors.
Power Generation
Efficient, reliable, climate-friendly power generation is vital for economic
development. With innovative technologies and products, Siemens is pushing
the limits of power plants efficiency and helping strike a viable balance between
climate protections, supply-security and cost efficiency in power generation.
From simple cycle power plants, steam power plants up to integrated
gasification combined cycle plants, Siemens ensures the highest levels of
efficiency currently possible throughout the entire power generation process.
The wide range of offerings includes solutions for automation of power grids
such as medium voltage switchgear and components.

STEEL MAKING
Steel making is the process of extraction of steel from iron and ferrous scrap.
The properties of steel are closely linked to its composition.
Properties of steel
Steel can have almost any combination of the following properties-
• LUSTRE
• CONDUCTIVITY
• MALLEABILITY
• DUCTILITY
• STRENGTH and DURABILITY
Types of steel
Steels are a large family of metals. All of them are alloys in which iron is mixed
with carbon and other elements. Different types of steel are produced according
to the properties required for their application and various gradient systems are
used to distinguish steels based on these properties.
Any batch of steel is manufactured according to the customer’s requirement or
specification. The specification will produce a steel with the properties that will
do the job for which it is required. According to the American Iron and Steel
Institute (AISI), steels can be broadly categorized into four groups based on
their chemical compositions:
1. Carbon Steels
2. Alloy Steels
3. Stainless Steels
4. Tool Steels

General Properties of Steels:
Properties Carbon
Steels
Alloy
Steels
Stainless
Steels
Tool Steels
Density (1000
kg/m3
)
7.85 7.85 7.75-8.1 7.72-8.0
Elastic Modulus
(GPa)
190-210 190-
210
190-210 190-210
Poisson's Ratio 0.27-0.3 0.27-
0.3
0.27-0.3 0.27-0.3
Thermal
Expansion (10-
6
/K)
11-16.6 9.0-15 9.0-20.7 9.4-15.1
Melting Point
(°C)
1371-1454
Thermal
Conductivity
(W/m-K)
24.3-65.2 26-48.6 11.2-36.7 19.9-48.3
Specific Heat
(J/kg-K)
450-2081 452-
1499
420-500
Electrical
Resistivity (10-
9
W-m)
130-1250 210-
1251
75.7-1020
Tensile Strength
(MPa)
276-1882 758-
1882
515-827 640-2000
Yield Strength
(MPa)
186-758 366-
1793
207-552 380-440
Percent
Elongation (%)
10-32 4-31 12-40 5-25
Hardness (Brinell
3000kg)
86-388 149-
627
137-595 210-620

Basic process of steel making
There are several reactions in iron and steel making process which involves
acids and bases. Manufacturing iron removing impurities is the first step in
production of steel. Iron is usually made from iron ore, coal and limestone-
although some plant around the world have developed alternative method of
iron manufacture.
1. Making iron in the blast furnace
The Blast furnace is a large steel structure about 90 meters high. It is lined with
refractory firebricks that can withstand temperatures approaching 2000®C .The
furnace gets its name from the method that is used to heat it. Preheated air(
mainly nitrogen) at about 1000®C is blasted into the furnace through nozzles
near its base.
The hot air blast to the furnace burns the coke and maintains the very high
temperatures that are needed to reduce the ore to iron. The reaction between air
and fuel generates carbon monoxide. This gas reduces the iron (III) oxide in
the ore to iron.
Iron(III) oxide + Carbonmonoxide = iron +
Carbondioxide
Fe₂O₃(S) + 3CO(g) = 2Fe(s) +
3CO₂(g)
Because the furnace temperature is in the region of 1500®C, the metal is
produced in a molten state and this runs down to the base of the furnace. The
furnace temperature is also high enough to decompose limestone into calcium
oxide.
Calcium carbonate = Calcium oxide + Carbon
dioxide
CaCo₃(s) = CaO(s) + CO₂(g)
This oxide helps to remove some of the acidic impurities from the ore.
Calcium oxide + Silica = Calcium silicate
Base Acid Salt

CaO(s) + SiO₂(s) = CaSiO₃(s)
The impurities are removed react with the calcium oxide to make a liquid slag
that floats on top of the molten iron. The slag is collected after the denser iron
has been run out of a
tap hole near the
bottom of the furnace.
The production of
iron in the blast
furnace is a
continuous process.
The furnace is heated
constantly and is
recharged with raw
materials from the top
while it is being
tapped from the
bottom. Iron making
in the furnace is
usually continues for
about ten years before the furnace lining have to be renewed.
The energy costs of the operation are kept to a minimum by collecting and
cleaning the hot gas that leaves the furnace. The gas contains a lot of carbon
monoxide. It can be re-used as a fuel for other steelmaking processes or to heat
up the air blast to the furnace.
2. Refining iron
The metal that leaves the Blast furnace contains between 4% to 5% of carbon.
This much carbon is makes a very hard brittle metal which is not much use. The
next step in the production of steel is to reduce the levels of the carbon and
other impurity elements in the hot metal.

3. Heat treatment
Heat treatment given to steel can affect its properties too. Cooling of red-hot
tool steel rapidly in cold water makes it harder and more brittle. We could have
made the same piece of metal softer by keeping it at red-heat foe longer and
then cooling it slowly. Heat treatment is another method that steelmaker uses to
make the properties of the steel match the job it has to do.
Routes to steel
Two methods of making steel are dominant in modern steel industries all over
the world.
• Route1: Basic Oxygen Steelmaking(BOS)
The hot metal from Blast furnace contains up to 4.5% of carbon. Steelmaking
reduces the carbon content to a level that matches the customer’s requirements.
This is often less than 0.1%. Basic Oxygen Steelmaking (BOS) makes steel
from the Blast furnace iron and small amount of scrap metal. Most of the metal
that is made in the BOS furnace is sold as bulk steel.
Blast furnace iron + scrap BOSFurnace Steel
The figure shows oxygen being
blown into the furnace or BOS vessel
through a water cooled oxygen lance.
This oxidizes carbon and the other
unwanted elements in the hot metal.
The carbon is oxidized to carbon
monoxide gas, which passes from the
converter to a cooling plant. After
cleaning, it can be re-used as a fuel
gas. The rest of elements in the metal
are converted to acidic oxides. They combined with the lime and other fluxes
that are added during the blow. This produces a slag that floats on the surface of
the metal.
The steel is tapped from the furnace when it is in correct temperature and
composition. The furnace is tilted and the molten metal is run out via the tap

hole into the ladle. Once the steel has been removed, the furnace is turned
upside down and the slag that is left inside runs into another ladle. The
solidified slag can be used in the production of cement and as an aggregate in
road building.
Basic oxygen sequence :-
I. BOS converter is charged first with the scrap. This is used as a
coolant. It is used to control the very high temperatures produced
by the violently exothermic reactions in the furnace.
II. Blowing: After charging, the furnace is blown by blasting oxygen
through a lance that is lowered into the molten metal. The furnace
needs no heating. Carbon is oxidized to CO and much of the
carbon in the metal escapes as this gas. Slag is formed is this stage.
III. After blow has continued for about 20 minutes, the metal is
sampled. The BOS process is now complete the furnace can be
tapped . Steel is run out of the tap hole into a ladle, separating it
from the lighter slag, which is later emptied as waste.
Removing gases and making it uniform:-
Some oxygen dissolves in the steel when the furnace is blown. Adding small
amounts of aluminum will remove the oxygen as aluminum oxide. This solid
forms a slag on the surface of the steel that is removed before the metal is cast.
The gases can be removed by vacuum degassing. This involves shaking the
molten metal at very low pressures, which allows dissolved impurity gases,
such as oxygen, to escape from the molten metal.
Next, the metal is stirred by blowing it with argon
gas.This ensures that the composition of the metal is
uniform. Stirring also helps to even out the temperature
throughout the liquid metal. The temperature is a critical
factor when the metal is being cast. The ladle arc
furnace in the picture can be used to adjust the
temperature of the metal before casting.
Once steel of the correct specification has been made, it
is ready for casting.
This way of giving the metal the basic shape that the customer wants. In the
past, it was usual to cast the molten steel from a ladle into moulds called ingots.

The steel was then shaped after it had solidified in the mould. This required re-
heating the ingot to soften it and then rolling in a steel mill.
Continuous casting:-
The modern steel industry uses continuous casting,
which is more efficient. This technique allows molten
steel from the ladle to be cast directly into the basic
shape that the customer wants. By adjusting the water-
cooled moulds in the continuous caster, steel sections
can be produced in the three basic shapes shown on
the right: slabs, blooms and billets.
The Basic Oxygen Steelmaking Process is the UK's major method for making
steel. Modern furnaces will take a charge of up to 350 tonnes and convert it into
steel in less than 40 minutes.
Route 2: Electric Arc Furnace (EAF)
We also make steel in the UK using the Electric Arc Furnace (EAF). This is
an electrically heated furnace that makes steel from scrap metal only.
Scrap EAF furnace Steel
The Electric Arc Furnace (EAF) offers an alternative method of bulk steel
manufacture. It makes steel from what would otherwise be unsightly and
environmentally damaging scrap metals. It also consumes much less energy
than the BOS furnace. Every tonne of EAF steel uses about 7.4 GJ of energy
compared with about 16.2 GJ for every tonne of BOS steel.

Furnace design
The EAF is a kettle-shaped structure with a removable lid. The three graphite
electrodes that heat the furnace pass through this lid, which can be swung back
when the furnace is being charged. The hearth of the EAF where the metal is
melted, is lined with a chemically basic and refractory material.
The sequence of operations is similar to that in the BOS furnace, except that,
after charging, the charge must be melted down. The furnace charge melts
when an electric arc passes between the electrodes and the scrap metal. The
temperature around the arc rises to 1200® C and a 100 tonnes charge can be
melted in about 60 minutes.
RH- Degasser:
R is the short form of Ruhrstahl. The first RH degasser was developed and
installed at the steelmaking company Ruhrstahl AG, Germany.
H is the short form of Heraeus . Heraeus was the main supplier of vaccum
pumps and constructed the vaccum pums for RH Degasser.
The RH-Degasser will be installed to fulfill the following tasks:
• Degassing
• Decarburization
• Chemical composition adjustments
• Temperature adjustments
• Vessel heating
Process description:
HYDROGEN REMOVAL: the final hydrogen content of a heat depends on the
pressure of vaccum vessel, the amount of lift gas and CO gas development.
Even fully killed heats can be treated due to intensive degassing supported by
lift gas.
For lowest hydrogen level the pressure must be lower than 2 mbar with
according treatment times 15-20 mins.

LIGHT TREATMENT: The liquid steel will be tapped un-killed or semi-killed
from convertor and partly deoxidized in the RH plant. The deoxidization will
occur due to the CO development by natural decarburization. The pressure
range depends on the CO equilibrium and is about 200-400mbar. After 10-12
mins treatment the final de-oxidation process will be carried out with Al or
others.
OXYGEN BLOWING PROCESS:- Forced Decarburization and heating of
unkilled heats. For the forced decarburization, oxygen will be blown only for a
few minutes in the pressure range of 5-30kpa. Heating of unkilled heats will be
executed during the decarburization process in case oxygen is blown for
decarburization, the blowing time will be extended until the required amount of
heat is added. The SIMENTAL oxygen blowing process features are short
blowing time with optimum oxygen efficiency.
CHEMICAL HEATING OF KILLED HEATS:- The Chemical heating process
is based on the fundamentals of exothermic process. In order to save alloying
agents such as C, Mn etc heating of killed heats will be conducted by a batch
additrion of aluminium and subsequent oxygen blowing.
QUICK DESKULLING BY OXYGEN JET: - Between the treatments the
oxygen jet can be used for a quick vessel deskulling. The deskulliong will be
executed for 10 or 15 minutres and large amount of skull can be removed.

STEEL MAKING PROCESS IN BRIEF
Steel Making Automation
Steelmaking automation supplies state-of-the-art solutions for
maximum performance and product quality throughout the entire steel
plant.
The unique advantage of this integrated approach is that it covers the
aspects of process stability, product quality and operation flexibility,
while safeguarding efficiency and profitability throughout the entire
plant life-cycle. Decades of experience with steelmaking technology,
combined with extensive automation expertise, is the basis for highly
advanced automation systems for every plant unit. Proven solutions for
power supply, drives, technological packages and process optimization
enable smooth production and the intelligent use of energy and raw
materials. And forward- looking service concepts ensure continuous
high availability of plant and equipment. Your investment is protected
by our standardized overall design with clear-cut interfaces.

PLC (PROGRAMMABLE LOGIC CONTROLLER)
PLC stands for programmable logic controllers. They are also referred to as
Programmable Controllers. They are used in commercial and industrial
applications. A PLC monitors inputs, makes decision based on it program, and
controls the output to automate a process or a machine.
• Basic operation of PLC
PLCs consist of input modules or points, a Central Processing Unit (CPU), and
output modules or points. An input accepts a variety of digital or analog signals
from various field devices (sensors) and converts them into a logic signal that
can be used by the CPU. The CPU makes decisions and executes control
instructions based on program instructions in memory. Output modules convert
control instructions from the CPU into a digital or analog signal that can be used
to control various field devices (actuators). A programming device is used to
input the desired instructions. These instructions determine what the PLC will
do for a specific input. An operator interface device allows process information
to be displayed and new control parameters to be entered.
Input
module
Central processing
unit (CPU)
Output
module
Programming Device Operating Interface

HARD-WIRED CONTROL
Before PLCs came into the picture, many control tasks were performed using
contactor or relay controls. This is often considered as ‘Hard-wired Control’.
Advantages of PLC
• Smaller physical size than hard-wire solutions.
• Easier and faster to make changes.
• PLCs have integrated diagnostics and override functions.
• Diagnostics are centrally available.
• Applications can be immediately documented.
• Applications can be duplicated faster and less expensively
Siemens PLCs
Siemens makes several PLC product lines in the SIMATIC S7 family. They are:
S7-200, S7-300, and S7-400
• S7-200
The S7-200 is referred to as a micro PLC because of its small size. The S7-200
has a brick design which means that the power supply and I/O are on-board.
The S7-200 can be used on smaller, stand-alone applications such as elevators,
car washes, or mixing machines. It can also be used on more complex industrial
applications such as bottling and packaging machines,

• S7-300 and S7-400
The S7-300 and S7-400 PLCs are used in more complex applications that
support a greater number of I/O points. Both PLCs are modular and expandable.
The power supply and I/O consist of separate modules connected to the CPU.
Choosing either the S7-300 or S7-400 depends on the complexity of the task
and possible future expansion. Your Siemens sales representative can provide
you with additional information on any of the Siemens PLCs.

TERMINOLOGY
The language of PLCs consists of a commonly used set of terms; many of which
are unique to PLCs. In order to understand the ideas and concepts of PLCs, an
understanding of these terms is necessary.
• Sensors-
A sensor is a device that converts a physical condition into an electrical signal
for use by the PLC. Sensors are connected to the input of a PLC. A pushbutton
is one example of a sensor that is connected to the PLC input. An electrical
signal is sent from the pushbutton to the PLC indicating the condition
(open/closed) of the pushbutton contacts.
• Actuators-
Actuators convert an electrical signal from the PLC into a physical condition.
Actuators are connected to the PLC output. A motor starter is one example of an
actuator that is connected to the PLC output. Depending on the output PLC
signal the motor starter will either start or stop the motor.
PLC
PLC MOTOR

• Discrete Input-
A discrete input, also referred to as a digital input, is an input that is either in an
ON or OFF condition. Pushbuttons, toggle switches, limit switches, proximity
switches, and contact closures are examples of discrete sensors which are
connected to the PLCs discrete or digital inputs. In the ON condition a discrete
input may be referred to as logic 1 or logic high. In the OFF condition a discrete
input may be referred to as
.
A Normally Open (NO) pushbutton is used in the following example. One side
of the pushbutton is connected to the first PLC input. The other side of the
pushbutton is connected to an internal 24 VDC power supply. Many PLCs
require a separate power supply to power the inputs. In the open state, no
voltage is present at the PLC input. This is the OFF condition. When the
pushbutton is depressed, 24 VDC is applied to the PLC input. This is the ON
condition.
• Analog inputs-
An analog input is an input signal that has a continuous signal. Typical analog
inputs may vary from 0 to 20 milliamps, 4 to 20 milliamps, or 0 to 10 volts. In
the following example, a level transmitter monitors the level of liquid in a tank.
Depending on the level transmitter, the signal to the PLC can either increase or
decrease as the level increases or decreases.

• Discrete output-
A discrete output is an output that is either in an ON or OFF condition.
Solenoids, contactor coils, and lamps are examples of actuator devices
connected to discrete outputs. Discrete outputs may also be referred to as digital
outputs. In the following example, a lamp can be turned on or off by the PLC
output it is connected to.
• Analog output-
An analog output is an output signal that has a continuous signal. The output
may be as simple as a 0-10 VDC level that drives an analog meter. Examples of
analog meter outputs are speed, weight, and temperature. The output signal may
also be used on more complex applications such as a current-to pneumatic
transducer that controls an air-operated flow-control valve.

• CPU-
The central processor unit (CPU) is a microprocessor system that contains the
system memory and is the PLC decision making unit. The CPU monitors the
inputs and makes decisions based on instructions held in the program memory.
The CPU performs relay, counting, timing, data comparison, and sequential
operations.
• Programming-
A program consists of one or more instructions that accomplish a task.
Programming a PLC is simply constructing a set of instructions. There are
several ways to look at a program such as ladder logic, statement lists, or
function block diagrams.
• Ladder logic-Ladder logic (LAD) is one programming language used with
PLCs. Ladder logic uses components that resemble elements used in a line
diagram format to describe hard-wired control. Refer to the STEP 2000
course Basics of Control Components for more information on line
diagrams.

• Ladder Logic Diagram-
The left vertical line of a ladder logic diagram represents the power or energized
conductor. The output element or instruction represents the neutral or return
path of the circuit. The right vertical line, which represents the return path on a
hard-wired control line diagram, is omitted. Ladder logic diagrams are read
from left-to right, top-to-bottom. Rungs are sometimes referred to as networks.
A network may have several control elements, but only one output coil.
Expanding the Application The application can be easily expanded to include
indicator
lights for RUN and STOP conditions. In this example a RUN indicator light is
connected to output Q0.1 and a STOP indicator light is connected to output
Q0.2.
It can be seen from the ladder logic that a normally open output Q0.0 is
connected on Network 2 to output Q0.1 and a normally closed Q0.0 contact is
connected to output Q0.2 on network 3. In a stopped condition output Q0.0 is
off. The normally open Q0.0 contacts on Network 2 are open and the RUN
indicator, connected to output Q0.1 light is off. The normally closed Q0.1 on
Network 3 lights are closed and the STOP indicator light,
connected to output Q0.2 is on.

I/O LIST:-
I/O List is a document containing list of instrumentation which serve as an input
or output of control system. Therefore, only the tag number that physically has a
cable which connects to the control system appears on I/O List.
In I/O list, the following information are generally stated
Tag number
Loop Number
Service description
P&ID Number
Type of Instrument
Location
I/O Type
Control System
Range or set point
The task with which we were associated was to identify the instruments from
the P&I Diagrams of different parts of the RH - Degasser plant and fill up the
corresponding Tag and Instrument numbers along with its description in the I/O
list.

The other type of task we performed was to fill up the function description list
from the corresponding I/O List and P&I Diagrams.
I/O List:-
Function Description List:-

HMI (Human Machine Interface)
Definition: The term HMI is used mostly in a manufacturing environment. The
human-machine interface (HMI) is where people and technology meet on the
plant floor. The HMI can be as simple as the grip on a drill or as complex as the
controls of an automated packing line.
This layer where humans and technology meet actually separates the human
operating the machine from the machine(s) itself. A good HMI should aid the
human in mentally mapping out the task needing to be performed with the
machine. The use of the HMI itself should be self evident or intuitive.
In manufacturing, a typical HMI could be a button that initiates a sequence of
events or a process. Or, a Windows based computer that uses software to
interface the human and the PLC, which initiates, stops or somehow controls
actions of a machine.
The user interface, in the industrial field of human machine-interaction, is the
space where interaction between humans and machines occurs. The goal of
interaction between a human and a machine at the user interface is effective
operation and control of the machine, and feedback from the machine which
aids the operator in making operational decisions. Examples of this broad
concept of user interfaces include the interactive aspects of computer operating
systemshttp://en.wikipedia.org/wiki/Operating_system, hand tools, heavy
machinery operator controls, and process controls. The design considerations
applicable when creating user interfaces are related to or involve such
disciplines as ergonomics and psychology.
. The user interface includes hardware (physical) and software (logical)
components. User interfaces exist for various systems, and provide a means of:
A user interface is the system by which people (users) interact with a machine
• Input, allowing the users to manipulate a system
• Output, allowing the system to indicate the effects of the users'
manipulation
Generally, the goal of human-machine interaction engineering is to produce a
user interface which makes it easy, efficient, and enjoyable to operate a machine
in the way which produces the desired result. This generally means that the
operator needs to provide minimal input to achieve the desired output, and also
that the machine minimizes undesired outputs to the human.

Ever since the increased use of personal computers and the relative decline in
societal awareness of heavy machinery, the term user interface has taken on
overtones of the graphical user interface, while industrial control panel and
machinery control design discussions more commonly refer to human-machine
interfaces.
Other terms for user interface include human–computer interface (HCI) and
man–machine interface (MMI).
SIMATIC WinCC is a supervisory control and data acquisition (SCADA) and
HMI system from Siemens. It can be used in combination with Siemens PCS7
and Teleperm control systems. WinCC is written for Microsoft Windows
operating system. WinCC uses Microsoft SQL Server for logging and comes
with a VBScript and ANSI C Application Programming Interface.
WinCC and PCS 7 are the first SCADA systems to be specifically targeted by
malware. The Stuxnet worm can spy on and even reprogram infected systems.
Some other HMI softwares are iFIXfrom Intellution and RSView from
Rockwell Software.Micro Panel, Mobile Panel, Personal Computer servers can
be used as HMI hardware.

Conclusion:
Human-machine interface is probably the sector in automation which has made
the greatest progress in the last few years. This progress is due to increasingly
sophisticated and user-friendly electronics and signal processing.
With the right choice of interface and its configuration, users can control
processes with ever greater exactness and undertake diagnostics and preventive
maintenance to increase productivity by reducing downtime.

The projects we have performed on the HMI Sinter Plant have been attached
herewith.
Project 1:-
Mixed Material Preparation System
With the help of a software provided by SIEMENS, accurate diagrams were
drawn as a soft copy which later with the help of PLC’s are used to execute a
plant’s design and its control.
As your single-source provider, Siemens’ human machine interface technology
SIMATIC HMI is engineered to meet the increasingly complex processes of
your machines and systems. SIMATIC HMI is optimized to meet your specific
human machine interface needs using open and standardized interfaces in
hardware and software, which allow efficient integration into your automation
systems.

Project 2:
Pipe & Instrument Diagram:-
Project 3:-
P&I Diagram for Plant Dedusting ESP:

Project 4:-
Waste Gas Cleaning System
Project 5:-
Waste Gas Cleaning System-Dust Transport

Conclusion:-
Various things were learnt through this industrial internship at Siemens.
It was a great privilege for me to get a golden opportunity for training in
SIEMENS VAI METALS TECHNOLOGIES PVT LTD. I got to see
practical implications of what I have studied in my engineering course. It
was a chance for me to learn how things work in industries & to get the
feel of corporate world.
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Siemens PLC & Automation Report

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