Bat PLC Day1

PBPLUS OIL AND GAS LEARNING HUB
BAT Practical PLC

Training (day 1)
www.pbplusoilandgas.com
PROGRAMMABLE LOGIC CONTROLLER
Table of Content
1. Basic definition and concept of Programmable logic controller

2. System components
3. The Input and Output System
Temperature Measurement Principle
Learning Objectives
At the end of this training every participant should be able to :
1. Understand the concept of PLC, its importance in the production industry
2. Identify basic PLC components
3. Identify all inputs and outputs in the RO Units
(zoom)
PLC Definition
A programmable logic controller (PLC) is a microprocessor-based industrial computer consisting
of three main parts: the controller or processor; the input; and the output. The PLC is used for the
monitoring and control of industrial processes.
They continually monitors the state of input devices and makes decisions based
upon a the program to control the state of output devices.
PLC Basic Concept and Development

PLC development started in the late 1960s/70s in the automotive industry
in the US. PLC were designed to replace hard-wired relay logic systems.
The hard-wired Systems was difficult for design engineers to alter the
automation process, there were a lot of rewiring carried out for a simple
change to be effected. Apart from that, the failure of a relay or component
could compromise the entire system.
The invention of the PLC eliminated the need for such cumbersome task
for engineers, it also eliminated the entire system failures due to the fault
on a particular relay. Richard E. Morley a.k.a Dick Morley was considered DICK MORLEY
the ‘father of PLC’, he was involved with the production of the first PLC 1932- 2017
(Modicon 084).
PLC System Components

A typical PLC system will have the units listed below, depending on the type of PLC, some will come all
built in one Unit (fixed/Compact) or it can be in modules (Modular) although we also have PLC with
different component units mounted in racks.
 The Processor (CPU)
 The Power supply Unit
 The Memory
 The Input and Output Unit
 A communication Interface
The PLC Processor

The PLC processor, also called the controller is the brain of the system, the Processor which is in the
central processing unit implements the programs and makes the decisions needed by the PLC to operate
and communicate with other units.. This is where the program data are stored, and where the decisions
that control the process or machine are made.
It scans the input data for information and
based On the stored programs, makes
decision to control the output.
The PLC Power supply

As with most electrical appliances, the PLC also need
the power to work, the size and design of the power
supply may depend on the manufacturer and the size of
the PLC. Typically most PLC power supplies are in 24V
DC (direct current). The mains AC power will either
come in 120V AC or 240V AC which will be converted
to DC for the PLC components.
There are various ways manufacturers can distribute
power to PLC components, some PLC may have a
power supply card sitting on a slot in the chassis while
connecting to other component through the bus. Others
may have the power looped by the installation
technician from the power slot to others
The PLC Memory

The PLC although operates ideally two types of memories, The Read Only Memory (ROM) and the
Random Access Memory (RAM). Other types of memory in use are the EPROM(Erasable
Programmable read only memory) and EEPROM (electronically erasable programmable read only
memory)
The ROM holds the PLC programs that cannot or shouldn’t be altered, Programs such as the operating
system of the PLC (OS) which is also referred to as the executive memory, it is usually developed and
installed by the manufacturer.
The RAM is a volatile memory, it can be erased once there is power failure, it holds the user programs
and other programs.
EPROM: This memory is more like a cloned ROM, it can be erased by an ultraviolet light and
reprogrammed.
EEPROM: this memory can also store programs like the ROM, it can be erased with voltage, it is
more common than EPROM’s.
Operating System
The operating system (OS) of a PLC includes tasks and programs designed to run automatically,
meaning they don’t require direct user commands to function. The operating System is not affected by
power failure or interruption of any kind, see details and functions of the OS in the next slide.
It organizes all the functions, sequences, and operations of the CPU not associated with a specific
control task. Key OS tasks include:
•Initiating a warm restart and hot restart
•Updating and outputting I/O process image tables
•Executing the user program
•Managing memory areas
•Detecting and calling interrupts
•Creating a connection with programmable devices
.
The Programming Device:

the programming device is the part of a PLC that gives you access to input your changes to the
PLC program. Here you can write your program and download this program to the CPU.
Without the programming device, it is difficult to interact or change the program.
While some manufacturers will provide a stand alone device for programing, other
manufactures will provide keys on the PLC where programs can be done on the HMI (human
machine Interface).
The Unitronic JAZZ controller can be programmed using a communication cable through the USB port
in your laptop
Function of the Programming Device:

Functions of a programming device:
• Develop a new PLC program in the PG device hard disc.
• Download the PLC program from the PG device to the CPU.
• Monitor the PLC program whilst the PLC is online to check various statuses.
• Modify the program in the PLC CPU or change certain arbitrary values.
• Transfer or upload the PLC program from the PLC CPU to the programming device’s
hard disc.
• Burn the EEPROM with the PLC program backup.
• Maintain a backup of the current PLC program on a programming device hard disc.
The Programming port:

A programming port is provided on the CPU to download any user program from a
programming device, to the CPU. The programming port is either a 9-pin serial COM port or
any other type depending on the vendor.
.
The Input/output module:
.PLC input devices can be Analogue or digital, analogue inputs are tagged AI while digital inputs are
tagged DI. Digital inputs are discrete, they can a 1 or a 0, that is ON or OFF. Such signal from a pressure
switch, flow stwitch are all digital signals. Anlague signals are not discrete, the have numerous positions to
attain, they fall between 0-20ma or 4-20ma. At 4ma representing the zero position and 20ma representing
100%, so if we have 16ma as a value, it means we are talking about 50%
A pressure switch Analogue temperature

Is a digital input probe
The Outputs:
The output signal could be analogue or digital, the output devices are final control elements, they
take actions in response to the state of the inputs based on the written program. Out devices that
uses digital signals can be a solenoid valve, a fans, blowers, timers, counters, light indicators etc.
Control valve uses analague signals, that is why they can open at different positions.
A blower is a A Valve is digital Analogue

output device Output device
Practical Session:
1. Demonstrating how the inputs interacts with output devices
2. Shutdown Systems with PLC

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PBPLUS OIL AND GAS LEARNING HUB

BAT Practical PLC

PROGRAMMABLE LOGIC CONTROLLER

1. Basic definition and concept of Programmable logic controller

Temperature Measurement Principle

PLC Basic Concept and Development

PLC System Components

The PLC Processor

The PLC Power supply

The PLC Memory

The Programming Device:

Function of the Programming Device:

The Programming port:

The Input/output module:

A pressure switch Analogue temperature

A blower is a A Valve is digital Analogue

1. Demonstrating how the inputs interacts with output devices

2. Shutdown Systems with PLC

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