Introduction to Industrial

Automation and Control

Lecture Vi
(Solomon B)
Introduction to Industrial Automation and Control
Introduction to Industrial Control Systems ( ICS)
It is a general term that encompasses several types of
control systems including:
Programmable Logic Controllers (PLC)
Distributed Control Systems (DCS), and
Supervisory Control and Data Acquisition (SCADA) systems,
They typically used in Industries like:
electrical, water, oil and gas, chemical, transportation, pulp and
paper, textail, food and beverage, and discrete manufacturing (e.g.,
automotive, aerospace, and durable goods.).
These control systems are critical to the operation of critical
infrastructures that are often highly interconnected and mutually
dependent systems.
Overview of SCADA, DCS, and PLCs
SCADA systems are:
highly distributed systems used to control geographically
dispersed assets, often scattered over thousands of square kms,
where centralized data acquisition and control are critical to
system operation.
used in distribution systems such as :
water distribution and wastewater collection systems,
oil and gas pipelines,
electrical power grids, and
railway transportation systems.
A SCADA control center:
Performs centralized monitoring and control for field sites
over long-distance communications networks, including
monitoring alarms and processing status data.
Based on information received from remote stations,
automated or operator-driven supervisory commands can be
pushed to remote station control devices, which are often
referred to as field devices.
Field devices control local operations such as opening and
closing valves and breakers, collecting data from sensor
systems, and monitoring the local environment for alarm
conditions.
SCADA System Implementation Example
Distributed Control Systems(DCS)
 DCSs are used to control production systems within the same
geographic location for industries such as oil and gas
refineries, water and wastewater treatment, electric power
generation plants, chemical manufacturing plants, and
pharmaceutical processing facilities.
 These systems are usually process control or discrete part
control systems.
 A DCS uses a centralized supervisory control loop to mediate
a group of localized controllers that share the overall tasks of
carrying out an entire production process.
Product and process control are usually achieved by deploying
feed back or feed forward control loops whereby key product
and/or process conditions are automatically maintained
around a desired set point.
To accomplish the desired product and/or process tolerance
around a specified set point, specific programmable controllers
(PLC) are employed in the field and proportional, integral,
and/or differential settings on the PLC are tuned to provide the
desired tolerance as well as the rate of self-correction during
process upsets.
DCSs are used extensively in process-based industries.
PLCs are :
Computer-based solid-state devices that control industrial equipment
and processes.
While PLCs are control system components used throughout
SCADA and DCS systems, they are often the primary components in
smaller control system configurations used to provide regulatory
control of discrete processes.
They are used extensively in almost all industrial processes.
They have a user-programmable memory for storing instructions for
the purpose of implementing specific functions such as:
 I/O control, logic, timing, counting, three mode PID control,
communication, arithmetic, and data and file processing.
 Control Loop. A control loop consists of
Sensors
Controller hardware such as PLCs
Actuators such as control valves, breakers, switches and motors
The communication of variables.
 Human-Machine Interface (HMI).
Operators and engineers use HMIs to
configure set points,
control algorithms, and
 adjust and establish parameters in the controller.
It also displays process status information and historical information.
 Remote Diagnostics and Maintenance Utilities.
Are used to prevent, identify and recover from failures.
Introduction to Programmable Logic Controllers (PLC's)
The Need for PLCs
Hardwired panels were very time consuming to wire, debug &
change.
GM identified the following requirements for computer
controllers to replace hardwired panels.
Solid-state not mechanical
Easy to modify input and output devices
Easily programmed and maintained by plant electricians
Be able to function in an industrial environment
The First Programmable Logic Controllers (PLCs)
Introduced in the late 1960’s
Developed to offer the same functionality as the existing relay
logic systems
Programmable, reusable and reliable
Could withstand a harsh industrial environment
They had no hard drive, they had battery backup
Could start in seconds
Used Ladder Logic for programming
A programmable logic controller (PLC) is a specialized
computer used to control machines and process.
It uses a programmable memory to store instructions
and specific functions that include On/Off control,
timing, counting, sequencing, arithmetic, and data
handling
Advantages of PLC Control Systems
Flexible
Faster response time
Less and simpler wiring
Solid-state - no moving parts
Modular design - easy to repair and expand
Handles much more complicated systems
Sophisticated instruction sets available
Allows for diagnostics “easy to troubleshoot”
Less expensive
Advantages of a PLC Control System
Eliminates much of the hard
wiring that was associated
with conventional relay
control circuits.
 The program takes the place of
much of the external wiring that
would be required for control of
a process.
Increased Reliability:
 Once a program has
been written and
tested it can be
downloaded toother
PLCs.
 Since all the logic is
contained in the
PLC’s memory, there
is no chance of
making a logic wiring
error
More Flexibility:
Original equipment
manufacturers (OEMs)
can provide system
updates for a process by
simply send in out a new
program.
It is easier to create and
change a program in a
PLC than to wire and
rewire a circuit.
End-users can modify
the program in the field
Lower Costs:
 Originally PLCs were
designed to replace relay
control logic. The cost
savings using PLCs have
been so significant that
relay control is becoming
obsolete, except for power
applications.
 Generally, if an application
requires more than about 6
control relays, it will
usually be less expensive to
Communications Capability:
 A PLC can communicate
with other controllers or
computer equipment.
 They can be networked to
perform such functions as:
supervisory control, data
gathering, monitoring
devices and process
parameters, and
downloading and uploading
of programs.
Faster Response Time:
 PLCs operate in real-time
which means that an event
taking place in thefield will
result in an operation or
output taking place.
 Machines that process
thousands of items per
second and objects that
spend only a fraction of a
second in front of a sensor
require the PLC’s quick
response capability.
Easier To Troubleshoot:
 PLCs have resident
diagnostic and override
functions allowing
users toeasily trace and
correct software and
hardware problems.
 The control program
can be watched in real-
time as it executes to
find and fix problems
PLC Architecture
PLC System
 PLC Architecture
 An open architecture design allows the system to be connected
easily to devices and programs made byother manufacturers.

 A closed architecture or proprietary system, is one whose

design makes it more difficult to connect devices and programs
made by other manufacturers.

 NOTE: When working with PLC systems that are proprietary

in nature you must be sure that any generic hardware or
software you use is compatible with your particular PLC.
 I/O Configurations
Fixed I/O
 Is typical of small PLCs
 Comes in one package, with
no separate removable units.
 The processor and I/O are
packaged together.
 Lower in cost – but lacks
flexibility.
 I/O Configurations

Modular I/O
Is divided by compartments into
which separate modules can be
plugged.
This feature greatly increases
your options and the unit’s
flexibility. You can choose from
all the modules available and mix
them in any way you desire.
 I/O Configurations
Modular I/O
When a module slides into the
rack, it makes an electrical
connection with a series of
contacts - called the backplane.
The backplane is located at the
rear of the rack.
 Power Supply
Supplies DC power to other
modules that plug into the rack.
In large PLC systems, this
power supply does not
normally supply power to the
field devices.
In small and micro PLC
systems, the power supply is
also used to power field
devices.
 Processor (CPU)
 Is the “brain” of the PLC.
 Consists of a microprocessor for
implementing the logic, and
controlling the communications
among the modules.
 Designed so the desired circuit can
be entered in relay ladder logic form.
 The processor accepts input data
from various sensing devices,
executes the stored user program,
and sends appropriate output
commands to control devices.
 I/O Section
Consists of:
 Input modules
 Output modules.
 I/O Section
Input Module
 Forms the interface by which
input field devices are
connected to the controller.
 The terms “field” and “real
world” are used to distinguish
actual external
 devices that exist and must
 be physically wired into the
system.
 I/O Section
Forms the interface by which
output field devices are
connected to the controller.
PLCs employ an optical
isolator which uses light to
electrical- ly isolate the
internal components from the
input and output terminals.
Programming Device
 A personal computer (PC) is the most commonly used programming
device
 The software allows users to create, edit, document, store and
troubleshoot programs
 The personal computer communicates with the PLC processor via a
serial or parallel data communications link
PC with appropriate
software
 Programming Device
 Hand-held programming devices are
sometimes used to program small PLCs
 They are compact, inexpensive, and easy Hand-held unit
to use, but are not able to display as much with display
logic on screen as a computer monitor
 Hand-held units are often used on the
factory floor for troubleshooting,
modifying programs, and transferring
programs to multiple machines.
 PLC Mixer Process Control Problem
 Mixer motor to automatically stir the
liquid in the vat when the temperature
and pressure reach preset values
 Alternate manual pushbutton control
of the motor to be provided
 The temperature and pressure sensor
switches
 close their respective contacts when
conditions reach their preset values
 Process Control Relay Ladder Diagram
 Motor starter coil is
energized when both
the pressure and
temperature switches
are closed or when the
manual pushbutton is
pressed
PLC Input Module Connections
 The same input field devices are used
 These devices are wired to the input module according to the
manufacturer’s labeling scheme
PLC Output Module Connections
Same output field device is used and wired to the output module
Triac
Triac switches motor ON and OFF in accordance with the control
signal from the processor
 PLC Ladder Logic Program

The format used is similar to that of the hard-wired relay circuit

PLC Ladder Logic Program

The symbols represent instructions

 PLC Ladder Logic Program

 The numbers represent addresses

 PLC Ladder Logic Program

 I/O address format will differ, depending on the PLC manufacturer. You give
each input and output device an address. This lets the PLC know where they are
physically connected
Entering And Running The PLC Program

To enter the program into the PLC, place the

processor in the PROGRAM mode and enter the
instructions one-by-one using the programming
device

To operate the program, the

controller is placed in the RUN
mode, or operating cycle
 PLC Operating Cycle

During each operating cycle, the controller

examines the status of input devices, executes the
user program, and changes outputs accordingly

The completion of one cycle of this sequence is called a scan. The

scan time, the time required for one full cycle, provides a measure of
the speed of response of the PLC
PLC Operating Cycle
PLC Operating Cycle

 Coil O/1 is energized when

contacts I/1 and I/2 are
closed or when contact I/3 is
closed.
 Either of these conditions
provides a continuous path
from left to right across the
rung that includes the coil.
 Modifying A PLC Program
 Relay ladder diagram for
modified process.
 The change requires that the
manual pushbutton
 control should be permitted to
operate at any pressure but not
unless the specified temperature
setting has been reached.
 If a relay system were used, it
would require some rewiring of
the system, as shown, to achieve
the desired change.
Modifying A PLC Program
 PLC ladder logic diagram for modified process.
 If a PLC is used, no rewiring is
necessary!
 The inputs and outputs are still the same.
 All that is required is to change the PLC
program
 PLCs Versus Personal Computers
Same basic architecture

PLC
 Operates in the industrial environment
 Is programmed in relay ladder logic
 Has no keyboard, CD drive, monitor, or disk drive
 Has communications ports, and terminals for input and
output devices
PC
 Capable of executing several programs simultaneously, in any order
 Some manufacturers have software and interface cards available so
that a PC can do the work of a PLC
 PC Based Control Systems
Advantages
 Lower initial cost
 Less proprietary hardware and software required
 Straightforward data exchange with other systems
 Speedy information processing
 Easy customization
PLC Size Classification
Handles up to 16 I/O points
Micro PLC
- Handles up to 32 I/O points
Physical size
Nano PLC
-Smallest sized PLC
Number of inputs and outputs (I/O count)
-Cost
PLC Size Classification

Allen-Bradley SLC-500 Family

- Handles up to 960 I/O points
Allen-Bradley PLC-5 Family
- Handles several thousand I/O points
PLC Instruction Set
The instruction set for a particular PLC type lists the different types of
instructions supported.

An instruction is a command that will cause a PLC to perform a certain

predetermined operation.
Typical PLC Instructions

 XIC (Examine ON) . . . . .Examine a bit for an ON condition

 XIO (Examine OFF) . . . . . . Examine a bit for an OFF condition
 OTE (Output Energize) . . . . Turn ON a bit (non retentive)
 OTL (Output Latch) . . . . . . Latch a bit (retentive)
 OTU (Output Unlatch) . . . . Unlatch a bit (retentive)
 TOF (Timer Off-Delay) . . . . . Turn an output ON or OFF after its rung has been
OFF a preset time interval
 TON (Timer On-Delay) . . . . Turn an output ON or OFF after its rung has been
ON for a preset time interval
 CTD (Count Down) . . . . . . . Use a software counter to count down from a
specified value
 CTU (Count Up). Use a software counter to count up to a specified value
 ?
Thank you!