PLC Based Control System

&
DDC Based Control System
BMC
 Control Strategies
Monitoring Sequential Control Closed Loop Control
Subsystems Subsystems Subsystems
Display the process Processes that follow Open Loop
state to the operator Predefined Sequence Closed Loop
Examples:
and draw attention to
Gas Fired Burner • Room Temperature
abnormal or fault 1. Energize Fan Starter Control
conditions which need 2. After 2 Minute, Open Gas Pilot Valve • Ship Autopilot Control
attention. and Operate Igniter for 2 Seconds. • Automatic Drug Delivery
3. If flame detected by Flame Detector, System
4. Open Main Gas Valve. • And many more…
• running/stopped
• forward/off/reverse
• fault/healthy
• Analog Quantities
like Level,
Temperature,
Voltage, Current
 Computer in Industrial Control
The first industrial computer application was probably a monitoring
system installed in an oil refinery in Port Arthur, USA in 1959.

(a)
a simple overview of a computer (b)
the computer as part of a control system
The instructions will define what action is to be taken as the
input data (from both the plant and the operator) change.

Speed is the highest priority in industrial control,

which has to be performed in ‘real time’.
 Requirements for industrial control

• Inputs of Industrial Computer comes from a vast number of devices.

• Although some of these are numeric (flows, temperature, pressures and
similar analog signals) most will be single-bit, on/off, digital signals.
• Similarly large amount of digital and analog output signals.

Hardwired Motor Starter Circuit Computer based Motor Starter

 Requirements for industrial control
Program for Motor Starter Using Computer : An Example

Program

repeat
start: = bitread(1);
stop: = bitread(2);
run: = ((start) or (run)) & stop;
bitwrite (10,run);
Until over
Requirement 1 : Modification and Expansion

• An industrial control program rarely stays the same for the whole of its life.
• There are always modifications to cover changes in the operations of the
plant.
• These changes will be made by plant maintenance staff, and must be made
with minimal (preferably no) interruptions to the plant production.
• Adding a second stop button and a second start button to above system
would not be a simple task.
 Requirements for industrial control

Requirement 2 : Time and Speed

• Computer has to respond to random events as they occur.

• An operator expects a motor to start (and more important to stop!) within a
fraction of a second of the button being pressed.

Requirement 3 : Sequential Programming

Control strategy has typical sequence e.g.

• start air fan,
• wait 10 s for air purge,
• open pilot gas valve,
• wait 0.5 s, start ignition spark,
• wait 2.5 s, if flame present open main gas valve.
Such sequences are difficult to write with conventional languages.
 Requirements for industrial control

Requirement 4 : Stable against Power Supply Interruption

• Some outputs must go back to the state they were in before the loss of
supply; others will need to turn off or on until an operator takes available
corrective action.
• The designer must have the facility to define what happens when the
system powers up from cold.

Requirement 5 : Steady against Environmental Variations and Disturbances

• An industrial computer will probably have to operate with temperatures as low as

−10 °C in winter and possibly over 45 °C in the height of summer, depending on the
climate of the geographical location.
• Exposed to Dust and Dirt more compared to other computers.
PLC: Programmable Logic Controllers

In late 1960, General Motors Company Produced Specification

of an Industrial Computer meeting all the above requirements
to replace its relay based logic with computer system in its
automated car plant.

Bedford Associates (later called Modicon) and Allen Bradley,

responded to General Motor’s specification, and developed a
computer system to meet the requirements.
PLC: Programmable Logic Controllers

In these early machines

there were essentially
four different types of
cards:

1 DC digital input card

2 DC digital output card
3 AC digital input card
4 AC digital output card

Each card would accept

16 inputs or drive 16
outputs. A rack of eight
cards could thus be
connected to 128
devices.
 Major Components of a Common PLC

POWER
SUPPLY

I M O M
N O U O
P D T D
U U PROCESSOR P U
From T L U L
SENSORS E T E To
Pushbuttons, OUTPUT
contacts, Solenoids,
limit switches, contactors,
etc. alarms
PROGRAMMING
DEVICE etc.
 Major Components of a Common PLC
POWER SUPPLY

Provides the voltage needed to run the primary PLC components

I/O MODULES

Provides signal conversion and isolation between the internal logic-

level signals inside the PLC and the field’s high level signal.

PROCESSOR

Provides intelligence to command and govern the activities of the entire PLC
systems.

PROGRAMMING DEVICE

Used to enter the desired program that will determine the sequence of
operation and control of process equipment or driven machine.
 From Relay Based Logic to PLC Programming – Ladder Diagram
• Ladder logic is the main programming method used for PLCs.
• Ladder logic has been developed to mimic relay logic.
Relay
• Device that uses a magnetic field to
control a switch.
• When a voltage is applied to the input
coil, the resulting current creates a
magnetic field.
• The magnetic field pulls a metal switch
towards it and the contacts touch,
closing the switch.
• The contact that closes when the coil is
energized is called normally open.
• The normally closed contacts touch
when the input coil is not energized.
Relay Symbols used in Ladder Diagram
• Relays are normally drawn in
C
schematic form using a circle to
represent the input coil.
• The output contacts are shown with
two parallel lines. Normally open NO
contacts are shown as two lines, and
will be open (non-conducting) when
the input is not energized.
• Normally closed contacts are shown
with two lines with a diagonal line NC
through them.
• When the input coil is not energized
the normally closed contacts will be
closed (conducting).
Relay based logic
• In this system the first relay on the left is used as normally closed, and
will allow current to flow until a voltage is applied to the input A.
• The second relay is normally open and will not allow current to flow until
a voltage is applied to the input B.
• If current is flowing through the first two relays then current will flow
through the coil in the third relay, and close the switch for output C.
Ladder Logic
This circuit would normally be
drawn in the ladder logic
form. This can be read
logically as C will be on if A is
off and B is on.

Here there are two inputs from

push buttons.
We can imagine the inputs as
activating 24V DC relay coils in
the PLC.
This in turn drives
an output relay that switches
115V AC, that will turn on a light. A PLC Illustrated With Relays
Ladder Logic Diagram Rung 1

Rung 2

Rung 1: If input A is on and input B is off, then power will flow through the
output and activate it. Any other combination of input values will result in the
output X being off.

Rung 2: On the left most part of the rung, power could flow through the top if C is off
and D is on. Power could also (and simultaneously) flow through the bottom if both E
and F are on. This would get power half way across the rung, and then if G or H is true
the power will be delivered to output Y.
Input Module/Card Connection
Output Module/Card Connection
 PLC Connection with I/O Devices

OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC
Typical Discrete Input Symbols for PLC Ladder Diagram

Normally Open Pushbutton

Normally Closed Pushbutton

Normally Open switch

Normally Closed switch

Normally Open contact

Normally closed contact

Analog Input

An analog input is an input signal that has a continuous signal.

Typical inputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V.
Below, a level transmitter monitors the level of liquid in the
tank. Depending on the level Transmitter, the signal to the PLC
can either increase or decrease as the level increases
or decreases.

Level Transmitter IN

PLC
Analog
Tank Input
Module
Digital Output

A discrete output is either in an ON or OFF

condition. Solenoids, contactors coils, lamps are
example of devices connected to the Discrete or
digital outputs. Below, the lamp can be turned ON or
OFF by the PLC output it is connected to.

OUT

PLC
Lamp
Digital
Output
Module
Analog Output

An analog output is an output signal that has a

continuous signal. Typical outputs may vary from 0
to 20mA, 4 to 20mA or 0 to10V.

Electric to pneumatic transducer

OUT
E Supply air
PLC 0 to 10V P

Analog
Output
Module
Pneumatic control valve
 Basic Function of a Typical PLC
Read all field input devices via the input interfaces,
execute the user program stored in application memory,
then, based on whatever control scheme has been
programmed by the user, turn the field output devices
on or off, or perform whatever control is necessary for
the process application.

This process of sequentially reading the inputs,

executing the program in memory, and updating the
outputs is known as scanning.
 PLC scanning

While the PLC is running, the scanning process includes

the following four phases, which are repeated
continuously as individual cycles of operation:

PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan
 AND OPERATION

A B C

Rung

Each rung or network on a ladder program represents a logic

operation.
In the rung above, both inputs A and B must be true (1) in order
for the output C to be true (1).
 OR OPERATION

A C

Rung

In the rung above, it can be seen that either input A or

B is be true (1), or both are true, then the output C is
true (1).
 NOT OPERATION

A C

Rung

In the rung above, it can be seen that if input

A is be true (1),
then the output C is true (0) or when A is (0),
output C is 1.
Advantages of PLC

1. Ease of Programming and Reprogramming in the plant.

2. A Programming Language that is based on relay wiring
symbols familiar to most plant operators and electrical
personnel.
3. High reliability and minimal maintenance.
4. Small physical size.
5. Ability to communicate with computer systems in the plant.
6. Moderate to low initial investment cost.
7. Rugged Construction.
8. Modular Design.
Example : Latching Motor Starter
 Distributed Digital Control

• Command Signal generated by computer act directly to

control the actuators in the plant.
• First Direct Digital Control Computer System was
Ferranti Argus 200 Installed in 1962 at ICI Ammonia
Soda Plant, at Fleetwood, Lancashire, England.
• It covered 128 control loops and 256 measurements.
Modes of Computer Control
Computer Control Network of DDC

• Computer control network performs

a wide variety of tasks: data
acquisition, servicing of video display
units in various laboratories and
control rooms, data logging from
analytical laboratories, control of
plant processes or pilot plant, etc.

• The computer network can be as

simple as an array of inexpensive PC's
or it could be a large commercial
distributed control system (DCS).
The elements of a commercial distributed control system network
The elements of a commercial distributed control system network
Data highway

Various parts of the plant processes and several parts of the DCS network
elements are connected to each others via the data highway (fieldbus).

The data highway is thus the backbone for the DCS system.

It provides information to the multi-displays on various operator control

panels, sends new data and retrieve historical data from archival storage, and
serves as a data link between the main control computer and other parts of
the network.

Host computer
The host computer is responsible for performing many higher level functions.

These could include optimization of the process operation over varying time
horizons (days, weeks, or months), carrying out special control procedure
such as plant start up or product grade transition, and providing feedback on
economic performance.
The elements of a commercial distributed control system network
Local Control Unit (LCU)

This is denoted as local computer in Figure. This unit can handle 8 to 16 individual
Control loops, with 16 to 32 analog input lines, 8 to 16 analog output signals and a
limited number of digital inputs and outputs.

Data Acquisition Unit

This unit may contain 2 to 16 times as many analog input/output channels as the LCU.
Digital (discrete) and analog I/O can be handled. Typically, no control functions are
available.

Batch Sequencing Unit

Typically, this unit contains a number of external events, timing counters, arbitrary
function generators, and internal logic.
The elements of a commercial distributed control system network

Local Display

This device usually provides analog display stations, analog trend recorder,
and sometime video display for readout.

Bulk Memory Unit

This unit is used to store and recall process data. Usually mass storage disks or
magnetic tape are used.
A Component of a Digital Control Loop
Schematic of Commercial DCS
Schematic of Commercial DCS
 Advantages of Direct Digital Control

• Digital systems are more precise.

• Digital systems are more flexible. This means that
control algorithms can be changed and control
configuration can be modified without having
rewiring the system.
• Digital system cost less to install and maintain.
• Digital data in electronic files are easier to deal
with.
• Operating results can be printed out, displayed on
color terminals, stored in highly compressed form.
 Telemetry
Tele : Remote and Metron : Measure

Telemetry is a process by which the measured physical

quantities, such as pressure, flow, temperature, level,
displacement, velocity, acceleration etc. are
transmitted to a convenient remote location or to
multiple location, in a form, suitable for displaying,
recording, actuating process etc.
Use of telemetry makes it possible to group several
instruments in a centralized control room to enable
operator to have a complete picture of condition in plant
without using long connecting pipes from various plant
sensors and transducers.
 Different Types of Telemetry Systems:

Pneumatic Telemetry System:

 Compressed Air is used to communicate the value of measured quantity
from one location to the other location.
 As no Electrical Form of transmission, no chance of short circuits,
electromagnetic interference. Considered as safe for hazardous area
sensitive to catch fire.
o Time lag in sending signal is critical as distance increase.
o More exposed to dirt and leakage.
 Different Types of Telemetry Systems:

Electrical or Electronic Telemetry System:

First advantage over Pneumatic telemetry is time required to send the signal is
infinitely small.

Electrical Telemetry:

1. Voltage Telemetry :
Measured variable is converted in AC or DC Voltage and then transmitted
to receiver.
Voltage Telemetry is affected by Line Resistance, Leakage and noise.
High Signal to Noise Ratio is required.
Can be used in Plants up to 300 Meters.

2. Current Telemetry :
Direct Current of 4-20 mA is used as transmission signal.
It is suffered from variation in supply voltage
Temperature variation increases line resistances.
 Different Types of Telemetry Systems:

Position Telemetry :
(Using Electrical System)

Selsyn – or Self Synchronous

generators as shown in figure
can be used to transmit an
angular position input to
angular position output.

No moving parts except at

transmitter input and receiver
output, so low maintenance.

For a single quantity of interest,

one set up is required.
 Different Types of Telemetry Systems:

Impulse Telemetry:
(Electronic Telemetry)

For a measured variable the

Impulse train of different forms
like
-Impulse Amplitude
-Impulse Spacing
-Impulse Duration
-Impulse Rate
Can be used to transmit the
signal.
 Different Types of Telemetry Systems:

Radio Telemetry Or Frequency Modulation Telemetry (Electronic Telemetry)

Original Signals to be transmitted

are converted to Frequency Signal
using V to F Converters. They are
called Subscribers Oscillators (SCO).

Boost all low frequency signals to

RF (Radio Frequency)
Send as Electromagnetic waves
over a large region.

Receive EM Waves, at FM receiver,

convert to Low freq. and then to
analog signal.

Wireless Transmission over a wide

area. Signal to Noise Ratio is also
good.
Used for large systems only.