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WEL-COME TO PLC PROGRAM

WEL-COME TO PLC PROGRAM. CONTROL SYSTEMS TYPES. 1) PLC 2) DCS 3) PC- Based Controls . PLC Sequentional logic solver PID Calculations. Advanced Subroutines BIT Operations. Data Transfer. Text Handling. PLCDCS Selection Criteria.

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WEL-COME TO PLC PROGRAM

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  1. WEL-COME TO PLC PROGRAM

  2. CONTROL SYSTEMS TYPES 1) PLC 2) DCS 3) PC- Based Controls. PLC • Sequentional logic solver • PID Calculations. • Advanced Subroutines • BIT Operations. • Data Transfer. • Text Handling.

  3. PLC\DCS Selection Criteria • Cost of hardware, software, Integration Engineering, Design, Installation, Start-up and Commissioning, Validation documentation and Execution, Training, Spare parts, Maintenance, System service contract and system life cycle. • Reliability, Flexibility, Scalability and Validatability. • Ease of Database configuration, Graphics development, Interlocks and Batch processing. • Integration of High-level Application. • Control Philosophy for Centralized versus Remote Operator Console or both. • Compliance with an Industry batch standard such as ISA SP88 and new Communication Protocol.

  4. PROGRAMMABLE LOGIC CONTROLLERS PLC • Sequentional logic solver • PID Calculations. • Advanced Subroutines • BIT Operations. • Data Transfer. • Text Handling. PLC Types • Nano (less than 1k RAM, 32 I/O) • Micro • Small • Large (8 to 64k RAM, 512 I/O More) Basic criteria for PLC Types • Memory Capacity • I/O Range • Packaging and Cost per Point

  5. Applications : • Machine controls. • Packaging. • Palletizing. • Material handling and similar Sequential task. Advantages of PLC : • They are fast and designed for the rugged industrial environment. • They are attractive on Cost-Per-Point Basis. • These Devices are less Proprietary ( E.g.. Using Open Bus Interface.) • These Systems are upgraded to add more Intelligence and Capabilities with dedicated PID and Ethernet Modules. Disadvantages of PLC : • PLC were Designed for Relay Logic Ladder and have Difficulty with some Smart Devices. • To maximize PLC performance and Flexibility, a number of Optional Modules must be added • This Product Family also create Training and Installation problems.

  6. PLC Types • Nano (less than 1k RAM, 32 I/O) • Micro • Small • Large (8 to 64k RAM, 512 I/O More) Basic criteria for PLC Types • Memory Capacity • I/O Range • Packaging and Cost per Point

  7. PLC Systems Installation in RCF 1. Siemens --- Ammonia I SIMATIC 115U 110U 2. Allen Bradley --- PGR,New Nitric Acid Plant PLC 5/25 and 5/10 3. Allen Bradley --- KCL/DAP Bagging Plant,Ammonia I SLC 5 4. GE Fanuc --- Ammonia Storage 90 - 30 Series 5. GE Fanuc --- New Bagging Plant 90 - 30 Series 6. Mitsubishi --- STP

  8. PLC Cycle Programmable controller Inputs Outputs Machine or Process

  9. O:0/7 O:0/7 PLC Signal Flow Output Modules Input Module Processor Memory Data Input Image Table Output Image Table I:0/6 I:0/6 I:1/4 O:1/5 Input Devices Output Devices Ladder Program O:0/7 I:0/6 I:1/4 O:1/5 I:1/4 O:1/5 Programming Terminal

  10. ALLEN BRADLEY PLC (DH+) Workstation with RSLogix5 Software Workstation PLC-5 Controller Data Highway Plus • Features : • Supports remote programming • Common, existing standard • Peer-to-Peer communications SLC-5/04 Controller

  11. ALLEN BRADLEY PLC ARCHITECTURE (ETHERNET) Laptop Internet PLC-5/20E Controller. SLC-5/05 Controller. PC Workstation Modem Ethernet PLC-5 Controller Ethernet Gateway. Data Highway Plus

  12. Comparison chart --- ALLEN BRADLEY PLC

  13. GE Fanuc - PLC GE Fanuc ‘s series 90-30 PLC Family. GE Fanuc 90/30 PLC 90 - 70 PLC’s Host Platform Wireless Modem • GE Fanuc PLC Architecture : Remote Platform Wireless Modem GE Fanuc 90/30 PLC H M I Display PC

  14. Siemens PLC Communication S5-115H S5-155H SINEC S5-155U S5-135U S5-100U

  15. Siemens PLC Architecture Program memory Memory submodule Internal program Memory (RAM) Process Image For Inputs And Outputs Processor Timer Counters Flags I/O Inputs Outputs I/O bus External Counters

  16. Siemens Programming Methods The program is generally written down before it is loaded into the programmable controller. This can be done in the form of a • Statement list ( STL ) • Control system flowchart ( CSF) or • Ladder diagram ( LAD ). The subsequent loading of the program into the S5-100U PC can take place in two ways : Online ( Direct to internal RAM ) or Off-line ( EEPROM or EPROM ), i.e., with the programmer connected or not connected to the programmable controller.

  17. Siemens S5-100U Specification

  18. Comparison chart --- SIEMENS - PLC

  19. PLC Architecture Evolution Programming Terminal • Mid - 1970s : Discrete Machine Control Connection is Point to Point PLC Programming Language : - Relay ladder logic - Flexibility in altering control system operation I/O

  20. PLC Architecture Evolution Reasonable Computer Running PLC Programming Software MS - DOS • Early - to - Mid 1980 : Discrete and Process Control PLC Programming Language : - Ladder Program - PID - Data Storage I/O

  21. Late 1980’s to early 1990’s : Discrete and Process Control Windows PC running PLC Programming Software PLC Architecture Evolution Connection in networked allowing Multiple PLC PLC PLC became a part of the developing enterprise resource system I/O

  22. Today :Enterprise Control Open Solutions NT - Based PC running Control Development Software PLC Architecture Evolution Program Download Connection CE Based Open Control Unit Ethernet - enterprise network connection I/O

  23. Ethernet Ethernet was originally designed by Digital, Intel and Xerox (DIX) in the early 1970’s and has been designed as a broadcast system. The original format for Ethernet was developed in Xerox Palo Alto Research center (PARC), California in 1972. The two inventors were Robert Metcalf and David Boggs. Ethernet version 1.0 and 2.0 followed until the IEEE 802.3 committee re-jigged the Ethernet II packet to form the Ethernet 802.3 packet. Nowadays you will see either Ethernet II (DIX) format or Ethernet 802.3 format being used. The ‘Ether’ part of Ethernet denotes that the system is not meant to be restricted only to one medium type, copper cables, fiber cables and even radio waves can be used. Briefly, stated Ethernet what is referred to as the Physical layer and the Data-link layers protocols. The physical layer defines the cable types, connectors and electrical characteristics. The Data link layer defines the format an Ethernet frames, the error checking method and the physical addressing method. As Ethernet is only a Physical/Data link layer other protocols need to be added on top of it to address the issues of routing, end-to-end data integrity and house specific network task are carried out.

  24. Ethernet 10Base5 Traditionally, Ethernet is used over ‘thick’ coaxial cable called 10Base5 ( the 10 denotes 10 Mbps, base means that the signal is baseband i.e, takes the whole bandwidth of the cable, 5 denotes 500m maximum length ). The minimum length between stations is 2.5m. The cable is run in one long length forming a ‘Bus Topology’. The segments are terminated by 50 ohm resistor and the shield should be grounded at one end only. 10Base2 Thin Ethernet (Thinnet) uses RG-58 cable and is called 10Base2 (the 2 denotes 200 mtr maximum length cable). Each station connects to the Thinnet by way of Network Interface Card (NIC). At each station the Thinnet terminates at a T-piece and at each end of the Thinnet run a 50 ohm terminator is required to absorb stray signals thereby preventing signal bounce.

  25. Ethernet 10BaseT Nowadays, it is becoming increasingly important to use Ethernet across Unshielded Twisted Pair (UTP) or Shielded Twisted Pair (STP), this being called 10BaseT (the T denotes twisted pair). UTP is installed in star wire format and Ethernet Hubs with UTP ports (RJ45) centrally located. Also there should be no more than a 11.5db signal loss and the minimum distance between devices is 2.5 meters. The advantages of the UTP/STP technology are gained from the flexibility of the system, with respect to moves, changes, fault finding, reliability and security. 10BaseF 10BaseF standard developed by IEEE 802.3 committee defines the use of Fiber for Ethernet. 10BaseFB allows upto 2 Km per segment and is defined for Backbone application such as cascading repeaters. 10BaseFL describes the standards for the Fiber optic links between stations and repeaters allowing upto 2 Km per segment on multimode Fiber.

  26. Ethernet The following table shows the RJ45 pin outs for 10BaseT :

  27. Segmented (star) topology Bus topology Ethernet Topology Workstation Workstation Workstation Workstation Switched Hub Controller Controller Controller Controller

  28. PLC conceptual overview Process Graphics History & Trend Alarm & Events SCADA configuration editor Other Aspect system OP Client SCADA Control Aspect OPC server SCADA server Real-time database opc Modbus comli Protocol xx Protocol yy Allen Bradley ABB Siemens GE Fanuc ….

  29. Process control Software characteristics The most important feature of process control system is that it needs to be reliable. The process control system used has to be completely crash-proof and any changes in the system need to be made on-line. The process control needs to be made real time, which means that it can update the I/O data table and process the control program in the time required by the process. A process control system that is deterministic refers to whether the operating system allows the highest priority task to work without interruption from task with lower priority. Software offerings in the automation and the process control fields must be versatile and open enough to address the needs of different applications. Finally the chosen solution must deliver tangible, quantifiable values such as : • Reducing project implementation time and cost. • Improving time-to-market. • Achieving higher production and quality. • Cutting maintenance and training cost. • Increasing profits.

  30. PC-based control system features Unlike the other systems, PCs provide a more open architecture making them ideal for improving, optimizing and integrating the overall automation process, as well as conducting control task. In addition PCs offer the following features : • Lower cost. • Ease of use. • Graphical user interface. • Easy integration of logic, motion and process control. • Simplified application development. • Software portability • Independence from proprietary control system. Using PCs enable the following functions, • Millisecond time stamping which is essential to utilities. • Real time control. • Sequence of events. • Alarming. • Data collection.

  31. Windows NT features Windows NT is gaining ground in open control because of the following advantages : • User acceptance. • Corporate interoperability • Ease of use. • Connectivity. • Scalability for small and large application. However, Windows NT has the following disadvantages : • Needs a lot memory and processing power. • Optimized for office, not control, requirements. • Requires a disk drive which may fail. • Depends on single vendor. • Reboots at unexpected times • Unstable operating system.

  32. QNX Features QNX real-time operating system, has evolved from the first-ever micro-kernel operating system for PCs into one of the best selling and most trusted operating systems for mission critical application. Today, QNX is the real time operating system in industrial automation, hand held devices, controllers and soft PLCs QNX is recognized as : • The fastest and most dependable real time operating system. • The most proven high speed, deterministic real time kernel. • Having a hard real time engine that gives PLC-style control. • Enabling data acquisition with milliseconds resolution. • Providing a fault-tolerant architecture on which you can run control, events, alarms in a virtually crash-proof environment.

  33. PLC Programming Standards The open, manufacturer-independent programming standard for automation is IEC 61131-3. You can thus choose what configuration interface you wish to use when writing your application : • Ladder Diagram • Instruction List • Function Block Diagram • Sequential Function Chart • Structured Text All users, be they plant electrician or computer scientists, thus have a configuration interface in which they can feel at home.

  34. Industrial IT Trends The availability of information is becoming increasingly crucial in the view of growing global competition. In future, a decisive competitive edge can only be achieved by providing the right information at the right time, in the right place and in the right form for the right person. these leading- edge application are continuously optimized and repositioned. Industrial IT consists of five components: • Engineering IT • Operation IT • Production IT • Optimization IT • Evolution / Information

  35. Industrial IT Trend Business Systems Sales & Marketing Planning & Scheduling Real-time Automation & Information ASSET OPTIMIZATION e-PRODUCTIVITY Plant & Process Eng. Operation & Maintenance Distribution Plant

  36. Thank you

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