Professional Certificate of Competency in PLCs & SCADA Systems – CAU

Assessment Instructions

1. You must answer ALL questions.

2. Complete your answers in a blue font.

3. Give concise, brief answers that address the questions.

4. Reference all content used from other sources.

5. Type your answers after each question without deleting the question.

6. Paste diagrams or scanned sketches directly into this answer sheet.

7. Save your document in Word format and include your name in the file title.

Part 1: Written Section

Q1. What is Set Point in Analog and Digital control?

Q2. What is Controlled Quantity in control system?

Q3. What is Error signal E in control system?

Q4. What are the four key layers to any significant Control System?

Q5. What are the different PLC architectures for high security applications? Provide a diagram.

Q6. Define process safety time.

Q7. List the components or devices that are used for RTU (Remote Terminal Unit) installation.

Q8. Briefly describe the control flags used in TCP (Transmission Control Protocol) Header.

Q9. What are the tasks involved in Installation and Commissioning phase?

Q10. What is Block Diagram of the process and list some of the items to be included in this document?

Q11. Write the sections involved in overall contract with specific vendor.

Q12. What are the modules to be included in operator interface?

Q13. What are the two main components involved in testing of the system?

Q14. What are the things to check when troubleshooting the analog input modules in a telemetry system?

Q15. What are the key requirements to be considered in setting up an effective earthing system?

Q16. Which different standards should be employed for the effective specification of a system? What should they cover?

Q17. List three firewall policy rules that are recommended for a SCADA system.

Q18. Sketch the diagram of SCADA system.

Q19. What are all the considerations in SCADA system?

Q20. Define RS-232 and describe its parts.

Q21. What are the transmission modes for exchange of data used in MODBUS?

Q22. What are the functions performed by physical layer in DNP3 (Distributed Network Protocol 3.0)?

Q23. Describe in brief about TCP/IP.

Q24. Write the guidelines to be followed while designing and executing panel wiring.

Q25. Describe briefly about wiring in Installation of Equipment.

Part 2: Practical Section

Q26. Build the following PLC code:
The input, connected to the PLC, is a normally-open push button.
a) If the circuit is left alone, what will the status of Light1 be? (On/Off)
b) If the circuit is left alone, what will the status of Light2 be? (On/Off)
c) Now, the push button is pressed in, and held in. What will the status of Light1 be? (On/Off)
d) What will the status of Light2 be? (On/Off)
e) Supply a screenshot of your program.

Q27. Design a Ladder-coded Timer sequencer for a traffic light circuit with the following:

• Red light on for 40 seconds

• Green light on for 30 seconds

• Amber (orange) light on for 15 seconds

• Continuous sequencer, which resets itself at the end of the sequence
  Provide a screenshot of the 3 output rungs that could be used with XIC/XIO logic to drive RedLamp, YellowLamp, and GreenLamp.

Q28. Build a counter in ladder code, incremented by a “Start_Button” which will switch on a light once a count of 5 is reached. Allow the counter to be reset. Provide a screenshot of your code.

Q29. Think in terms of a typical START / STOP circuit for industrial equipment. This exercise must make use of a latching / holding contact. When the buttons are pressed, a light (representing the motor) must go on and off as per the button pressed. Provide a screenshot of your code.

Q30. Build a SCADA Project using CITECT SCADA:

• Mimic screen for a process with two tanks (tank1 and tank2) and a pump transferring liquid from tank1 to tank2.

• Show the status of the pump on the screen.

• Include an emergency stop button to shut down the process.

• Display tank levels on the screen.
  a) Provide a screenshot of your entire screen.
  b) Run the program and provide a screenshot of the CITECT message after compilation.

Brief Summary of Assessment Requirements

The assessment for the Professional Certificate of Competency in PLCs and SCADA Systems is divided into two main sections: Written Section and Practical Section. The key requirements are as follows:

Part 1: Written Section

• Answer all questions with concise and clear explanations.

• Demonstrate understanding of core PLC and SCADA concepts, including:

  • Analog and digital control (set points, controlled quantities, error signals)

  • Control system layers and PLC architectures

  • Remote Terminal Unit (RTU) components

  • Communication protocols (TCP/IP, MODBUS, DNP3)

  • SCADA system design, considerations, and firewall rules

  • Panel wiring, earthing, and installation guidelines

• Include diagrams or sketches where required.

• Reference all sources appropriately.

Part 2: Practical Section

• Implement practical PLC and SCADA tasks using software tools (Codesys and CITECT SCADA).

• Key tasks include:

  • Building simple ladder logic circuits with push buttons and lights

  • Designing traffic light timers and counters using ladder logic

  • Implementing START/STOP circuits with latching/holding contacts

  • Creating SCADA mimic screens for a two-tank system with a pump and emergency stop

• Take screenshots to demonstrate implementation and simulation results.

Overall Requirements

• Complete all tasks in Word format with student name in the title.

• Ensure answers are original, concise, and referenced, while diagrams and screenshots are clearly presented.

• The assessment evaluates both theoretical understanding and practical application of PLCs and SCADA systems.

Approach by the Academic Mentor

The academic mentor guided the student through the assessment in a step-by-step process, ensuring both understanding and practical implementation:

Step 1: Understanding the Written Section

• Objective: Ensure the student understands theoretical concepts before practical implementation.

• Method:

  • Reviewed each question, highlighting the key concept (e.g., Set Point, Error Signal, SCADA considerations).

  • Explained definitions, examples, and real-world applications of PLC/SCADA concepts.

  • Encouraged the student to reference course materials and industrial standards for accurate answers.

Step 2: Structured Answering

• Objective: Develop concise, complete answers with proper structure.

• Method:

  • Instructed the student to answer each question directly below the question, preserving numbering.

  • Advised the use of bullet points for lists and diagrams for visual clarity.

  • Highlighted the importance of referencing any content drawn from external sources.

Step 3: Preparing for Practical Tasks

• Objective: Translate theoretical knowledge into practical implementation in PLC and SCADA software.

• Method:

  • Guided the student through installation and setup of Codesys and CITECT SCADA.

  • Demonstrated ladder logic programming for simple circuits (push button, lights).

  • Explained timers, counters, and latching mechanisms for industrial automation.

  • Showed step-by-step how to create a mimic screen, including tank levels, pump status, and emergency stop functions.

Step 4: Simulation and Testing

• Objective: Ensure functional correctness of PLC and SCADA programs.

• Method:

  • The mentor supervised simulations to verify ladder logic circuits and SCADA screens.

  • Instructed the student to capture screenshots of working programs and compile messages to demonstrate proper operation.

  • Discussed troubleshooting techniques for errors in wiring, timers, or control logic.

Step 5: Compilation of Assessment

• Objective: Present answers and practical work in a professional, organized manner.

• Method:

  • Ensured Word document included:

    • Written answers in blue font

    • Diagrams, screenshots, and mimic screens properly embedded

    • File named according to assessment guidelines

  • Reviewed for completeness, accuracy, and proper referencing before submission.

Outcome and Learning Objectives Covered

By following this guided approach, the student achieved the following outcomes:

Outcome:

• Completed all written and practical questions satisfactorily.

• Produced functional PLC programs and SCADA mimic screens.

• Demonstrated understanding of industrial control systems and safety considerations.

• Submitted a professional, organized, and fully referenced document.

Learning Objectives Covered:

1. Understanding analog and digital control concepts, set points, error signals, and controlled quantities.

2. Knowledge of PLC architectures, RTU components, and SCADA system design.

3. Application of communication protocols (TCP/IP, MODBUS, DNP3) in industrial automation.

4. Ability to design and troubleshoot ladder logic circuits, timers, counters, and START/STOP systems.

5. Implementation of a SCADA mimic screen with process monitoring and emergency stop functionality.

6. Practical skills in panel wiring, earthing, system commissioning, and installation standards.

7. Awareness of system security requirements, firewall rules, and standards for industrial automation.

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