Practical Programmable Logic Controllers (PLCs) for Automation and Process Control. Contents

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1 Practical Programmable Logic Controllers (PLCs) for Automation and Process Control Contents 1 Introduction to the PLC Introduction Basic Block Diagram of the PLC Size of the PLC System Components of the PLC Systems PLC and Process Interaction Number Systems and Codes 8 2 Processors, Power Supply and Programming Devices Introduction To The PLC Hardware Processors (CPU) PLC Power Supply Programming Device 17 3 Memory System and I/O Interaction Memory Systems Digital I/O Interaction Analog I/O Interaction 26 4 Digital Input/Output Systems Basics of Discrete I/O Systems Types of Discrete Field Devices Types of Discrete Input Modules Types of Discrete Output Modules 34 5 Analog Input/ Output Systems Basic of Analog I/O Systems Types of Analog Field Devices Types of Analog Input Modules Types of Analog Output Modules 47

2 6 Special Function I/O and Serial Communication Interfacing Introduction Fast Response Input Module Counter Module Positioning Module Stepper Motor Positioning Module 61 7 Good Installation Practices Introduction PLC Modules PLC Rack PLC Panel Internal Wiring PLC Panel Power Supply Cabling Between PLC And Field Devices Cabling PLC And Control Room Computers PLC Earthing Specific PLC Installation Requirements Control Room Requirements 83 8 Fundamentals of PLC Programming Introduction PLC Programming Steps Programming Languages Basic Logic Instructions Timers Counter Program Flow Control Instructions Data Load and Transfer Instructions Arithmetic or Math Instructions Data Acquisition Introduction A Typical Data Acquisition System Aliasing and the Sampling Theorem Data Coding System Analog and Digital Control Introduction Analog Inputs Signal Filtering Analog Display Analog Control Application of PID Control Alternative Forms of Analog Control 145

3 11 Fault Tolerance - Spreading the Risk How Reliable Is Our Equipment? Project Planning Key Questions Two Key Strategies The People! Primary Loop Control and Interlocking The Field Devices Communications DCS Structure PLC System Options The Costs Utilities Spare PLCs I/O Allocation Backing up Current Plant Data Power Supplies Peripheral Equipment Future Directions with Smart Instruments Highway Addressable Remote Transducer (HART) ASCII Communications Devices Intelligent Communication Devices Data Communications Introduction RS RS Modbus Serial Ethernet and TCP/IP Introduction Mbps Ethernet Mbps Ethernet ( Fast Ethernet ) Gigabit Ethernet Industrial Ethernet IP (Internet Protocol) ARP and RARP TCP UDP Field buses Background Plant Automation Hierarchies HART 218

4 15.4 DeviceNet Profibus Foundation Fieldbus Operator Interfaces Introduction Ergonomic Considerations High Security PLC Systems Introduction and Terminology Background to Safety Control Systems Safety Systems Concepts Resistance to Random Hardware Failures Architectures for Safety PLCs Objections to Standard PLCs Used for Safety Characteristics of Safety PLCs Hardware Characteristics of a Safety PLC Software Characteristics of a Safety PLC Design Safety PLCs Redundant Architectures for PLCs- High Availability with High Integrity Conclusion of Safety PLCs Application Software Safe Networking Classifications and Certification Summary of High Security PLCs System Programming and Implementation Introduction Taking Process Inputs Creating I/O List Deciding Hardware Configuration of PLC system I/O Address Assignment Developing Program Structure Tips for Developing a PLC Program Program Verification and Simulation Creating Documentation Best Practice Documentation What Is a Manual? Types of Manuals Planning the Manual Drafting the Manual Reviewing the Manual 310

5 20 HMI (Human Machine Interface) Introduction Design Consideration of HMI Hardware Interface Between PLC and HMI Software Interface Between PLC and HMI Electrical Design and Construction Introduction PLC Enclosure Panel Layout Electrical Wiring of Panel Gudielines for Panel Electrial Design Functional Specification of the System Introduction System Requirement Specification Function Specification of the System Hi-tech Mining Circulation of the Functional Specification Checklist of Factors for Selection of an I/O Module Selection of the System Testing of the System Fuzzy Logic Introduction Understanding Fuzzy Logic The Rules of Fuzzy Logic Fuzzy Logic Example Using Rules And Patches The Achilles Heel of Fuzzy Logic Configuration of the System Initial Concepts Training on the System Input/Output Database Creation General Database Design Tips Installation and Commissioning Introduction Control Room MCC Requirements Installation of Equipment Loop Testing Manual Control Automatic Control System Handover Maintenance and Training 402

6 26 Working Example of PLC Programs Introduction Control Philosophy Typical PLC Program for Drives Understanding Advanced Programming Techniques 413 Bibliography 419 Appendices Appendix A Glossary 421 Appendix B ASCII Table 437 Appendix C Number Systems 439 Appendix D Logic Fundamentals 449 Appendix E Practicals: Part Appendix F Basic Program 471 Appendix G Functional Logic Diagrams 479 Appendix H Practicals: Part 2 483

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