Basic concept of PLC which controls the process.pptx

Basic concept of Automation System.it includes how the PLC contols Process control system

1. SCADA SYSTEM with PLC CONTROLLER

2. Basic Concept of PLC 12. Basic Concept of SCADA System Hardware Descrption 13. Downloading,installation and Licensing PLC practical wiring 14. Graphics Software overview TIA Portal Downloading,installation and Licensing 15. Creating the Graphical projects TIA Portal V16 Software overview 16. Communication Configuration (interfacing Creating New Project PLC to SCADA System) Hardware Configuration 17. User Adminstration Configuration General Programming 18. Archiving and back up of SCADA project Downloading and uploading PLC programs 19. Troublshooting SCADA System Archiving and Retrieving PLC projects 20. Mini Project under guidiance PLC Troublshooting System SCADA SYSTEM TRAINING COVERAGE Titel der Präsentation 25. . 05 .20 24 Seite

3. Process Control System PROCESS Process refers to the methods of changing or refining raw materials to create end products. The raw materials during process are transferred, measured, mixed heated or cooled, filtered, stored, or handled in some other way to produce the end product PROCESS CONTROL is the method which is used to control process variables when manufacturing products.

4. process Industries control the production process for three reasons: Reduce variability :-Process control can reduce variability in the end product, which ensures a consistently high-quality product Increase efficiency :-Some processes need to be maintained at a specific point to maximize efficiency Ensure safety :-A run-away process may result if manufacturers do not maintain precise control of all of the process variables. The consequences of a run-away process can be disastrous

5. Three tasks are needed to control a process :- Measurement of process variables Comparison with the given set point Adjustment to avoid the error or the difference with the set point :- in order to control the process variable of a given process we need to measure, compare and adjust the process variable to keep the given set point value of the process variable. Process Control System...

6. Process Control System...

7. Titel der Präsentation 22.01.2019 Seite So we can conclude from the above that we need three type of instruments to control a process:- MEASURING ELEMENTS(SENSORS) CONTROLLERS CONTROL ELEMENTS (ACTUATORS) Process Control System...

8. Sensors are devices that can detect physical variables(conditions ) of a given process such as temperature, pressure , level, flow, motion etc and have the ability to give a measurable output. We can categorize them in to two groups as follows. Discrete process measuring elements Analog/continuous process measuring elements MEASURING ELEMENTS (SENSORS) Process Control System...

9. Process Control System... symbols of Discrete measuring and control elements for electrical schematic diagrams

10. Common examples of Discrete process measuring elements Process Control System... Push Buttons : Start Push button, Stop Push button and Emergency etc. Limit switch : target not contacting the switch Proximity switch : target far away Pressure switch : low pressure (or even a vacuum) Level switch : low level (empty) Temperature switch : low temperature (cold) Flow switch : low flow rate (fluid stopped)

11. Temperature measuring elements : Commonly thermocouple and RTD Pressure measuring elements : Commonly pressure Transmitters level measuring elements : Differenital ,Radar and Ultrasonic Transmitters Flow measuring elements : Mass flow meter,Magnetic Flow meters,Vortex flow meters, Weight measurement : Commonly Load cells Analog Measuring elements Process Control System...

12. ii. FINAL CONTROL ELEMENTS (ACTUATORS) Final control element is a device that receives out put signal from controller and takes an action at the process according to the given instruction from controller to avoid the error b/n PV and SV of the given process. common control devices are:- solenoid valves control valves Contactors,Drives or variable speed drives (pumps, etc.)

13. CONTROLLERS Controller is a device that receives data from measurement instruments (Sensor, Transducer or Transmitter ) and compares that data with the programmed set point value , and if necessary generates a signal output to a control element( actuators ) to take a corrective action. We can catagorized controllers as following:- Mechanical(such as pneumatic, hydraulic) controller electronic controller Programmable controller

14. electronic controller Thermocouple Alarm Teamperature Control System

15. Basic Concept of PLC

16. What is PLC? A programmable logic controller (PLC) is an industrially computer-based unit that performs discrete or continuous control functions in a variety of processing plant and factory environments

17. The 6 basic hardware components that make up a PLC are: Processor (CPU) Mounting System Power Supply Input & Output Interface Communication Interface Programming Device These main PLC hardware components are found in all PLC systems regardless of manufacturer, type and size . They are the essential hardware elements that make up every PLC system.

18. Basic Concept of PLC… PLC Hardware Block Diagram

19. Basic Concept of PLC… PLC Processor (CPU) The most crucial PLC hardware component Sometimes the PLC processor is also referred as the PLC controller or PLC CPU (Central Processing Unit The PLC processor contains 3 fundamental components: PLC CPU (Central Processing Unit) PLC Memory PLC Programming port

20. PLC CPU (Central Processing Unit) Basic Concept of PLC… t he CPU is responsible for Program scanning (such as ladder logic) program executing- executes a program that is stored as a sequence of machine language instructions in main memory Handling data storage -by executing instructions that have been read from memory, in which,tell the CPU what operations need to be performed on particular data items stored in memory or registers. Directing data flow -When an instruction is fetched from memory it is sent through the control unit where it is decoded Controlling communication-

21. PLC Memory Basic Concept of PLC… The PLC uses the memory: to store the program for processing by the CPU and to store data for input and output processing and execution. if we have a large PLC program then we will require a PLC controller with a large integrated memory capacity to accommodate PLC Programming Port the communication protocol used for the PLC programming port includes RS232, RS485 and Ethernet.

22. Basic Concept of PLC… Titel der Präsentation 25. . 05 .20 24 Seite PLC is a continuously monitor the status of devices connected as inputs. Based upon a user written program ,stored in memory it control the status of devices connected as output The I/O interfaces provide the connection between the PLC and the information providers (inputs like pushbuttons, sensors,…) and the controllable devices (outputs like pumps, valves, relays, lamps,…).

23. 22 Jan. 2019 Titel of the presentation Page Basic Concept of PLC… PLC like any PC, consists of: Central Processing Unit. Input/Output (I/O) interface system.

24. Basic Concept of PLC… Final Block Diagram of CPU interacting with I/Os

25. Functional interaction of a PLC system Basic Concept of PLC…

26. Basic Concept of PLC… The major components of a common PLC.

27. Basic Concept of PLC…

28. PLC Hardware Mounting Systems Basic Concept of PLC… The hardware mounting system of a PLC provides the means to physically connect the various hardware components of the PLC system. PLC hardware mounting systems can vary from one PLC manufacturer to another and can also vary depending on the type of PLC used The 3 main PLC mounting systems used in industrial automation projects are: Rack mounted PLC Rail mounted PLC Panel mounted PLC

29. Basic Concept of PLC… uses a mechanical mounting system in order to physically connect the PLC processor and other PLC hardware components together commonly used in modular and distributed type PLC systems They are well suited to service higher end and plant wide applications where multiple PLC racks and large numbers of inputs and outputs are required. They have a fixed number of hardware module slots and generally have an orderd hardware module layout. such as power supply module, PLC processor module, communication modules then input and output modules. Rack mounted PLC

30. Basic Concept of PLC…

31. Basic Concept of PLC… Some PLC manufacturer use different terminology to describe their rack mounted PLCs. Terms such as chassis, backplane, base, base rack and base module are all examples of different terminology to describe rack mounted PLCs. Siemens uses the term PLC rack for their S7-400 PLC mounting system. Allen Bradley uses the term PLC chassis for their ControlLogix PLC mounting system. Omron CS1, Schneider Modicon M340 and Delta AH series PLCs uses the term PLC backplane Koyo, Toshiba and Yokogawa use the term PLC base to describe their PLC mounting systems

32. Basic Concept of PLC… Siemens S7-1500 muonting rack

33. Basic Concept of PLC… Rail Mounted PLC

34. Basic Concept of PLC… Panel Mounted PLCs A panel mounted PLC uses a mounting system that directly mounts the PLC and its hardware components without the additional need for a rack or rail . A panel mounted PLC will have mounting holes molded into the PLC housing and PLC modules, usually around the edges of the PLC housing.

35. Historical Background Titel der Präsentation Seite Basic Concept of PLC… First commercial & successful Programmable Logic Controllers was designed and developed by Modicon as a relay replacer for General Motors automobile manufacturing industry to provide flexible, rugged and easily programmable controllers to replace hard-wired relay logic systems Later ,in late 1970’s,the micro processor became reality & greatly enhanced the role of PLC permitting it to evolve from simply relay  to the sophisticated system. 25. . 05 .20 24

36. Titel der Präsentation Seite Basic Concept of PLC… Principle of operation First, CPU scans the inputs and then it executes the program. After executing the program, the CPU updates the outputs PLC scans its program top to bottom and rungs in the program are scanned from left to right order 25. . 05 .20 24

37. PLC Vs Relay Control Titel der Präsentation Seite Basic Concept of PLC… Relay Control PLC Control 25. . 05 .20 24

38. Titel der Präsentation Seite Basic Concept of PLC… Relay Control PLC Control 25. . 05 .20 24

39. Titel der Präsentation Seite Basic Concept of PLC… 25. . 05 .20 24 # Contents PLC  Relay 01 Basic Programmable Logic Control (PLC) is a solid-state computerized industrial controller that performs software logic by using input & output modules, CPU, memory, and others.  Relay is an electro-mechanical switching hardware device (Hardware Switching Device). 02 Function PLC plays a monitoring as well as controlling role in designing circuits. Relay plays only a controlling role in the designing circuit. Monitoring is not so easy with a relay. 03 Working In the PLC, we can write the program using  different types of programming languages . In the Relay, we cannot write the program. 04 Operation  ( Digital & Analog Signals ) PLC is operated on the digital system. Relay is operated on the analog system. 05 Design You can easily modify the designing circuit. Modification of the electronic circuit is more difficult as compared to PLC. 06 I/O PLC has more capabilities of  input and output modules . The relay does not have more capabilities. 07 Flexibility PLC provides more flexibility than the relay. The relay provides less flexibility. 08 Fault  You can easily find the fault by using the software. It is very hard to find fault in the Relay circuit. 09 Types of PLC & Relay There are two types of PLC as- Compact PLC Modular PLC Following the list of types of the relay- Electromagnetic Relay Thermal Relay Induction Relay

40. Thank you 22 Jan. 2019 Titel of the presentation Page In cooperation with: Placeholder for logo of cooperation partner (please delete if not appropriate) Implemented by