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Practical Programmable Logic Controllers

(PLCs) for Automation and Process Control


Contents

1 Introduction to the PLC 1
1.1 Introduction 1
1.2 Basic Block Diagram of the PLC 2
1.3 Size of the PLC System 3
1.4 Components of the PLC Systems 3
1.5 PLC and Process Interaction 5
1.6 Number Systems and Codes 8

2 Processors, Power Supply and Programming Devices 13
2.1 Introduction To The PLC Hardware 13
2.2 Processors (CPU) 13
2.3 PLC Power Supply 17
2.4 Programming Device 17

3 Memory System and I/O Interaction 21
3.1 Memory Systems 21
3.2 Digital I/O Interaction 24
3.3 Analog I/O Interaction 26

4 Digital Input/Output Systems 29
4.1 Basics of Discrete I/O Systems 29
4.2 Types of Discrete Field Devices 30
4.3 Types of Discrete Input Modules 31
4.4 Types of Discrete Output Modules 34

5 Analog Input/ Output Systems 39
5.1 Basic of Analog I/O Systems 39
5.2 Types of Analog Field Devices 40
5.3 Types of Analog Input Modules 41
5.4 Types of Analog Output Modules 47




6 Special Function I/O and Serial Communication
Interfacing 53
6.1 Introduction 53
6.2 Fast Response Input Module 54
6.3 Counter Module 55
6.4 Positioning Module 58
6.5 Stepper Motor Positioning Module 61

7 Good Installation Practices 67
7.1 Introduction 67
7.2 PLC Modules 69
7.3 PLC Rack 71
7.4 PLC Panel Internal Wiring 72
7.5 PLC Panel Power Supply 72
7.6 Cabling Between PLC And Field Devices 74
7.7 Cabling PLC And Control Room Computers 78
7.8 PLC Earthing 78
7.9 Specific PLC Installation Requirements 81
7.10 Control Room Requirements 83

8 Fundamentals of PLC Programming 87
8.1 Introduction 87
8.2 PLC Programming Steps 89
8.3 Programming Languages 91
8.4 Basic Logic Instructions 101
8.5 Timers 103
8.6 Counter 107
8.7 Program Flow Control Instructions 111
8.8 Data Load and Transfer Instructions 114
8.9 Arithmetic or Math Instructions 117

9 Data Acquisition 123
9.1 Introduction 123
9.2 A Typical Data Acquisition System 123
9.3 Aliasing and the Sampling Theorem 124
9.4 Data Coding System 127

10 Analog and Digital Control 135
10.1 Introduction 135
10.2 Analog Inputs 135
10.3 Signal Filtering 136
10.4 Analog Display 137
10.5 Analog Control 137
10.6 Application of PID Control 139
10.7 Alternative Forms of Analog Control 145


11 Fault Tolerance - Spreading the Risk 147
11.1 How Reliable Is Our Equipment? 147
11.2 Project Planning 147
11.3 Key Questions 147
11.4 Two Key Strategies 147
11.5 The People! 149
11.6 Primary Loop Control and Interlocking 149
11.7 The Field Devices 149
11.8 Communications 149
11.9 DCS Structure 150
11.10 PLC System Options 151
11.11 The Costs 151
11.12 Utilities 151
11.13 Spare PLCs 151
11.14 I/O Allocation 152
11.15 Backing up Current Plant Data 152
11.16 Power Supplies 152

12 Peripheral Equipment 153
12.1 Future Directions with Smart Instruments 153
12.2 Highway Addressable Remote Transducer (HART) 154
12.3 ASCII Communications Devices 158
12.4 Intelligent Communication Devices 158

13 Data Communications 159
13.1 Introduction 159
13.2 RS-232 159
13.3 RS-485 164
13.4 Modbus Serial 169

14 Ethernet and TCP/IP 181
14.1 Introduction 181
14.2 10 Mbps Ethernet 181
14.3 100 Mbps Ethernet (Fast Ethernet) 184
14.5 Gigabit Ethernet 185
14.6 Industrial Ethernet 186
14.7 IP (Internet Protocol) 193
14.8 ARP and RARP 203
14.9 TCP 205
14.10 UDP 212

15 Field buses 215
15.1 Background 215
15.2 Plant Automation Hierarchies 216
15.3 HART 218


15.4 DeviceNet 221
15.5 Profibus 229
15.6 Foundation Fieldbus 233

16 Operator Interfaces 239
16.1 Introduction 239
16.2 Ergonomic Considerations 239

17 High Security PLC Systems 247
17.1 Introduction and Terminology 247
17.2 Background to Safety Control Systems 251
17.3 Safety Systems Concepts 251
17.4 Resistance to Random Hardware Failures 260
17.5 Architectures for Safety PLCs 262
17.6 Objections to Standard PLCs Used for Safety 263
17.7 Characteristics of Safety PLCs 267
17.8 Hardware Characteristics of a Safety PLC 267
17.9 Software Characteristics of a Safety PLC 268
17.10 Design Safety PLCs 269
17.11 Redundant Architectures for PLCs- High Availability with
High Integrity 271
17.12 Conclusion of Safety PLCs 276
17.13 Application Software 276
17.14 Safe Networking 277
17.15 Classifications and Certification 280
17.16 Summary of High Security PLCs 281

18 System Programming and Implementation 283
18.1 Introduction 283
18.2 Taking Process Inputs 283
18.3 Creating I/O List 284
18.4 Deciding Hardware Configuration of PLC system 286
18.5 I/O Address Assignment 288
18.6 Developing Program Structure 291
18.7 Tips for Developing a PLC Program 293
18.8 Program Verification and Simulation 295
18.9 Creating Documentation 297

19 Best Practice Documentation 299
19.1 What Is a Manual? 300
19.2 Types of Manuals 300
19.3 Planning the Manual 302
19.4 Drafting the Manual 307
19.5 Reviewing the Manual 310





20 HMI (Human Machine Interface) 315
20.1 Introduction 315
20.2 Design Consideration of HMI 317
20.3 Hardware Interface Between PLC and HMI 325
20.4 Software Interface Between PLC and HMI 326

21 Electrical Design and Construction 327
21.1 Introduction 327
21.2 PLC Enclosure 327
21.3 Panel Layout 329
21.4 Electrical Wiring of Panel 331
21.5 Gudielines for Panel Electrial Design 332

22 Functional Specification of the System 335
22.1 Introduction 335
22.2 System Requirement Specification 337
22.3 Function Specification of the System 342
22.4 Hi-tech Mining 346
22.5 Circulation of the Functional Specification 376
22.6 Checklist of Factors for Selection of an I/O Module 376
22.7 Selection of the System 378
22.8 Testing of the System 379

23 Fuzzy Logic 381
23.1 Introduction 381
23.2 Understanding Fuzzy Logic 382
23.3 The Rules of Fuzzy Logic 383
23.4 Fuzzy Logic Example Using Rules And Patches 385
23.5 The Achilles Heel of Fuzzy Logic 387

24 Configuration of the System 389
24.1 Initial Concepts 389
24.2 Training on the System 389
24.3 Input/Output Database Creation 390
24.4 General Database Design Tips 398

25 Installation and Commissioning 399
25.1 Introduction 399
25.2 Control Room MCC Requirements 399
25.3 Installation of Equipment 400
25.4 Loop Testing 400
25.5 Manual Control 400
25.6 Automatic Control 401
25.7 System Handover 401
25.8 Maintenance and Training 402


26 Working Example of PLC Programs 403
26.1 Introduction 403
26.2 Control Philosophy 403
26.3 Typical PLC Program for Drives 405
26.4 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 1 453

Appendix F
Basic Program 471

Appendix G
Functional Logic Diagrams 479

Appendix H
Practicals: Part 2 483

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