PLC (Programmable Logic Controller)

Objectives: 1. Identify major components of PLCs and their functions 2. Identify typical analog and discrete inputs and outputs 3. Read a basic Ladder logic diagram, statement list, flow chart and function block diagram. Introduction:

PLCs act as controllers for machines and processes. They are used for ESD(Emergency Shut Down). Functions: 1. monitors inputs 2. makes decisions 3. controls output in order to automate machine and processes. Basic PLC operation: Primary parts of PLC are input modules, CPU and output modules.

Input modules: It accepts variety of analog or digital inputs from various sensors and converts them to logical signals that can be used by the CPU. CPU: CPU makes decisions and executes control instructions based on program in its memory. Output modules: Converts control instructions from CPU into signals that can be used to control various field devices. Programming device: used to install instructions that determine what the PLC will do in response to specific inputs. Operator module: The operator interface allows process information to be displayed and new control parameters to be entered. EXAMPLE:

Hard wired control: Prior to PLC many control tasks were done with contactors and relays hard wired together. Circuits were first had to be designed and drawn up. Then components had to be installed. PLCs can perform same tasks as hard wired controls and more complex functions as well. The connections between field devices and relays take place inside PLC instead of external wiring. So installations are easier and modification also, just by changing program only.

Advantages of PLCs: small size easier and faster system changes centrally available diagnostics immediate documentation faster and less costly duplication of applications integrated diagnostics and override functions

Basic Terminology: Sensor: Sensor is a device that converts a physical signal into an electrical signal for use by PLC .Sensors is connected to inputs of PLC. Example: Push button.

Actuators: It converts electrical signals from PLC outputs into physical conditions. Example: motor starter. Depending upon the state of PLC output the motor starter will either start or stop the motor.

Discrete inputs: Also called as digital inputs, recognize either ON or OFF conditions from discrete sensors. Examples of discrete sensors are toggle switches, proximity switches, push button and limit switches.

Analog inputs: An analog input can accept signals that vary on a continuous basis. Typical analog inputs vary from 4-20 milliamps or 0-10V. Example: A level transmitter monitors the level of liquid in a tank. Depending on the type of level transmitter the voltage on PLC will decrease or increase as the liquid level increases.

Discrete outputs: A discrete output also called as digital output i.e. either ON or OFF. Example: solenoids, lamps, contactors, etc.

Analog outputs: An analog output varies continuously. The output may be as simple as 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 to on more complex applications such as current to pneumatic transducer that controls an air-operated flow- control valve.

CPU (Central Processing Unit): It is a microprocessor that is the PLC decision making unit. It also contains system memory. CPU monitors the inputs and makes decisions based on instructions held in its program memory. It performs relay, counting, timing, data comparison and sequential operations.

Program/Ladder Logic:

Reading Ladder Logic Diagrams: The left vertical line represents the power or energized conductor. The output elements or instructions represent neutral or return circular path. Ladder logic diagrams are read from left to right and top to bottom. The ladder logic rungs are referred to as networks. A network may have several control elements but only one output coil.

Ladder logic and Statement list: 10.0, 10.1 and Q0.0 are first instruction combination. If inputs 10.0 AND 10.1 are energized output relay Q0.0 energizes.

In second instruction combination, if either 10.4 or 10.5 energizes, output relay Q0.1 energizes.

Function block diagrams: It is another way to represent a program. Each function has a name to designate its specific task, and is indicated by a rectangle with its name inside. Inputs are shown on left and outputs on right.

PLC Scan cycle: The PLC program is executed as a part of repetitive process referred to as a scan. A PLC scan begins with the PLC reading the status of its inputs. The application program is executed based on this information. Once the program is completed the PLC performs internal diagnostics and communication tasks. The scan cycle completes by updating the outputs and then starts over. The cycle time of a PLC scan depends on size of the program, number of inputs and amount of communication required.

DCS(Distributed Control System):

A distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring. DCS is a very broad term used in a variety of industries, to monitor and control distributed equipment. Applications:

Electrical power grids and electrical generation plants Environmental control systems Traffic signals Radio signals Water management systems Oil refining plants Metallurgical process plants Chemical plants Pharmaceutical manufacturing Sensor networks

Dry cargo and bulk oil carrier ships

Elements of DCS: A DCS typically uses custom designed processors as controllers and uses both proprietary interconnections and communications protocol for communication. Input and output modules form component parts of the DCS. The processor receives information from input modules and sends information to output modules. The input modules receive information from input instruments in the process (or field) and transmit instructions to the output instruments in the field. Computer buses or electrical buses connect the processor and modules through multiplexer or demultiplexers. Buses also connect the distributed controllers with the central controller and finally to the Humanmachine interface (HMI) or control consoles. See Process automation system.

Some Important terms related to PLC and DCS :

SOE/SOR/FOE: SOE-sequence of events, SER-sequence event recorder and FOA-fast out alarm. Honeywells uses SER term. Rockwell uses FOA term. A sequence of events recorder (SER) is an intelligent standalone microprocessor based system, which monitors external inputs and records the time and sequence of the changes. Sequence of events recorders usually has an external time source such as a GPS or radio clock. When wired inputs change state the time and state of each change is recorded. SERs enable rapid root cause analysis after multiple events have occurred due to the secure recording of the sequence of events in the order of occurrence. SERs are therefore utilized as a diagnostic tool to minimize plant downtime. SERs are often interfaced with distributed control system (DCS), or programmable logic controller (PLC).

Redundancy: Redundancy is a common approach to improve the reliability and availability of a system. Adding redundancy increases the cost and complexity of a system design and with the high reliability of modern electrical and mechanical components, many applications do not need redundancy in order to be successful. However, if the cost of failure is high enough, redundancy may be an attractive option. The three main models described in this paper are Standby Redundancy, N Modular Redundancy, and 1: N Redundancy.

Standby Redundancy Standby redundancy, also known as Backup Redundancy is when you have an identical secondary unit to back up the primary unit. The secondary unit typically does not monitor the system, but is there just as a spare. The standby unit is not usually kept in sync with the

primary unit, so it must reconcile its input and output signals on takeover of the Device Under Control (DUC). This approach does lend itself to give a bump on transfer, meaning the secondary may send control signals to the DUC that are not in sync with the last control signals that came from the primary unit. You also need a third party to be the watchdog, which monitors the system to decide when a switchover condition is met and command the system to switch control to the standby unit and a voter, which is the component that decides when to switch over and which unit is given control of the DUC. The system cost increase for this type of redundancy is usually about 2X or less depending on your software development costs. In Standby redundancy there are two basic types, Cold Standby and Hot Standby. Cold Standby

In cold standby, the secondary unit is powered off, thus preserving the reliability of the unit. The drawback of this design is that the downtime is greater than in hot standby, because you have to power up the standby unit and bring it online into a known state. This makes it more challenging to reconcile synchronization issues, but do to the length of the time it takes to bring the standby unit on line, you will usually suffer a big bump on switchover. Hot Standby

In hot standby, the secondary unit is powered up and can optionally monitor the DUC. If you use the secondary unit as the watchdog and/or voter to decide when to switch over, you can eliminate the need for a third party to this job. This design does not preserve the reliability of the standby unit as well as the cold standby design. However, it shortens the downtime, which in turn increases the availability of the system. Some flavors of Hot Standby are similar to Dual Modular Redundancy (DMR) or Parallel Redundancy, which are covered in the next section. These naming conventions are commonly interchanged. The main difference between Hot Standby and DMR is how tightly the primary and the secondary are synchronized. DMR completely synchronizes the primary and secondary units. However, some literature loosely uses the term DMR for any redundancy model that use two units. N Modular Redundancy N Modular Redundancy, also known as Parallel Redundancy, refers to the approach of having multiply units running in parallel. All units are highly synchronized and receive the same input information at the same time. Their output values are then compared and a

voter decides which output values should be used. This model easily provides bump less switchovers. This model typically has faster switchover times than Hot Standby models, thus the system availability is very high, but because all the units are powered up and actively engaged with the DUC, the system is at more risk of encountering a common mode failure across all the units. There are techniques to help avoid this risk that are mentioned later in this paper. Deciding which unit is correct can be challenging if you only have two units. Sometimes you just have to choose which one you are going to trust the most and it can get complicated. If you have more than two units the problem is simpler, usually the majority wins or the two that agree win. In N Modular Redundancy, there are three main typologies: Dual Modular Redundancy, Triple Modular Redundancy, and Quadruple Redundancy. Dual Modular Redundancy

Dual Modular Redundancy (DMR) uses two functional equivalent units, thus either can control the DUC. The most challenging aspect of DMR is determining when to switch over to the secondary unit. Because both units are monitoring the application, you have to decide what to do if they disagree. You either need to create a tiebreaker vote or simply designate the secondary unit as the default winner, assuming it is more trustworthy than the primary unit. You may be able to trust the secondary unit more if the primary is normally in control and if regular diagnostics are run on the secondary to help insure its reliability, but this is very application specific. The average cost increase of a DMR system is about twice that of a non-redundant system, factoring in the cost of the additional hardware and the extra software development time. Triple Modular Redundancy

Triple Modular Redundancy (TMR) uses three functionally equivalent units to provide redundant backup. This approach is very common in aerospace applications where the cost of failure is extremely high. TMR is more reliable than DMR due to two main aspects. The most obvious reason is that you now have two standby units instead of just one. The other reason is that in TMR, you commonly see a technique called diversity platforms or diversity programming applied. In this technique, you would use different software or hardware platforms on your redundant systems to prevent common mode failure.

Quadruple Modular Redundancy Quadruple Modular Redundancy (QMR) is fundamentally similar to TMR but using four units instead of three to increase the reliability. The obvious drawback is the 4X increase in system cost. CPU: It has a key. It can work in three states, which are run, stop and idle. COM card (Communication card): It is used for communication with HMI and SOE. HBD(Horizontal Bus Driver) VBD(Vertical Bus Driver) WD (Watch Dog): It looks after (a) scan time jump, (b) error beat, (c) voltage drop and (d) checks similarity between outputs. PLC to DCS communication/sub system communication/Third party communication: When PLC and DCS are of different companies or make then EIM (Ethernet Interface Module) card is used. BNC connector is used to convert BNC to Ethernet using EIM card. FTEB(Fault Tolerant Ethernet Bridge):

Signal flow diagram of signal from plant to PLC:

Junction Box

Barrier

Patch Card

DI Rack

HBD

VBD

CPU

DO Rack