HISTORY OF PLC

•American Automobile Industry was looking for a reliable

Electronic System to replace the Relay panels that controlled
the sequence operations in its manufacturing lines.
•In 1968, General Motors floated an enquiry for a system
giving specific requirements of the controls.
•Bedford Associates developed the first PLC ( named 084 )
which met the requirements of General Motors. Several
orders poured in. B/A started a new Co. to make PLCs and
named the Co. “ MODICON “
•Bedford’s chief designer Dick Morley is considered as the
father of PLC. Several Cos started making PLCs later.
•“MODICON” changed hands --- Gould Electronic, USA --
•AEG,Germany--& now with French “Schneider Electric”
 EVOLUTION OF CONTROL SYSTEMS

CHAOS  ORDER  SYSTEM

CONTROLS

MANUAL AUTOMATIC
Hand Control Self Acting
Signal manipulation Algorithm based (P I D )

COMPUTER SYSTEM
Analogue Digital
Data Loggers
PLCs
DDCs
SCADA
DCS
 CONTROLLER : REQUIREMENTS/LIMITATIONS
REQUIREMENTS:
# Measurement Accuracy
# Fast Response to signal changes
# Output Resolution
# Analogue/Digital signal compatibility
# Real time control outputs
# Multi/Sequential outputs
# Power failure: Hold on/Reset feature
# Program change by operator

LIMITATIONS:
• No. of multi input/outputs very limited ( 8 I / 4 O )
• Resolution limited by range
• Analogue/Digital combine - not possible
• Real time activity – not possible
• Power failure : output hold – very complicated
• In-built program/Algorithm change - very difficult
 PLCs : Advantages

• Multiple inputs/outputs ( > 1000s ) – analogue & digital

• Extended temperature range of operation ( ambient upto 55 deg C )
• Immunity to electrical noise
•Resistance to vibration & noise in the surroundings ( limited extent )
•Power failure : Program protection by non volatile memory/battery backup
•Real time system response ( CPU speed )
•Adaptive to many program languages : Ladder logic to Basic, C+ etc.,
•Current models – Change /edit program by PC or Laptop and also
software based trouble shooting possible
•Back up storage of application program by EEPROM, EPROM possible
 PLC -- Application Areas

• Sequential Relay Logics

• Ex.: Boiler sequence, CNC m/c control, ESD system for plants
• Motion Control
• Cargo area Cranes, Material transfer, Machine safety interlocks (vibr. )
• Process Control
• Batch process, R/M mix & feed, Engine/Aux. interlock & trip, UMS alarms
• DCS in Continuous Process
• Monitoring, control, record keeping, energy savings, MIS etc.,

• Networking
• Layer-3 automation for networking different computer systems like Plant/
Mtce / Prod.Schedule/Marketing computers interlink etc.,
 PLC BLOCK DIAGRAM
TO OTHER
INTELLIGENT
DEVICES

PUSH LIGHT
BUTTONS RELAYS
LIMIT COMMUNICATIONS
SWITCHES PROCESSOR VALVES

MEMORY PROGRAM &

TRANSMITTERS
DATA
LOCAL
POWER

THUMB
WHEELS 9 1 4 BATTERY
CENTRAL PROCESSOR POWER

PROCESSOR
PROGRAM CARD OR
RACK

PROGRAMMING
UNIT
INTERNAL STRUCTURE OF A MICROPROCESSOR

Cache Memory

Data
Instruction register and decoder in/out

Accumulator and temporary register

Address of
location in
memory
Working registers

Program Counter and Status register Control

signals

ALU

Control and timing circuits

MICROPROCESSOR WITH SUPPORT CHIPS

Address bus

On chip
32
cache
C/S Dynamic
16 KB RAM
controller
32 Address
CPU

32 Data Bus

32 Dynamic
Clock Transceiver RAM
generator

Data

Bus
controller
 PLC Inputs & Outputs

• INPUTS:
• Analogue types: Signals from transmitters, transducers etc.,
4 to 20 mA dc, 1 to 5 V dc, pulse inputs etc.,
• Digital types: On/Off switches, valve limit switches,doors/dampers status

switches, motor status contacts, crane/hoist limit switches etc.,

• OUTPUTS:
• Analogue: Output signals to control valves ,servo motors,pneumatic cylinders
typically as 4 to 20mA, 1 to 5V dc signals, & pulse outputs
• Digital : On/Off voltage outputs to operate devices like solenoids, ann.
Lamps,actuated valves,hooters, lamp ckts, loads like A/c s etc.,
 Signal Conditioning of I/O s
• a) Analogue Signals:
•> Temp/flow/press/level etc., to 4 to 20 mA current signals
•> Current to pneumatic pressure for control valve actuation:4-20mA to 3-15psi
•> Pneumatic to current for transmission: 3-15psi to 4-20mA
•> Position Transducers like LVDT for engine shaft movement , alignment etc.,
• b) Digital Signals :
•> Relay inputs/outputs -- potential free contacts
•> Transistor switches -- interface to proximity switches
•> Triac switches -- ckt. Condition, motor control electronics etc.,
• c) DAC / ADC:
•> Analogue to digital and digital to analogue signal conversions in computer
systems for input conditioning and display needs
• d) Opto couplers / Isolators:
•> For Fibre optic cable signal transmission over long distances & signal isolation.
 PLC IN SHIPS

SIGNAL CONDITIONING

• To amplify low level signals to match receiving indicator/controller

• To match impedance level from transducer to amplifier level
• To adjust dynamic frequency range of transducer signal to suit inputs
• To linearize output with respect to transducer characteristics
• To convert amplitude to pulse, phase etc., to enable noise immunity

DC Signal

Passive Sensor Amplifier Low Pass Filter DC

DC Bridge
Output

AC Signal

DC
Active Sensor AC Bridge Amplifier Demodulator Active Filter
Output
 PLC IN SHIPS
Signal Conversions

Analogue to Digital Conversion is done when the output device is Digital like LED/LCD
Indicators, Pulse input circuits, Digital computers etc.,

Digital to Analogue Conversion is done when the digital controller’s output is to actuate
an analogue device like a Control valve , meter indication etc.,

Optocouplers ( Optoisolators )

Out
Input CPU CPU Relay
put

LED Phototransistor
Contact

Active sensors like Inductive/Capacitive proximity switches and pulse output

transducers can be connected to PLC inputs thro’ the process of sourcing &
sinking of signals.

PLC can also provide power to operate output devices like solenoids, bulbs etc.,
thro’ Fused terminals so as to protect the PLC’s internal circuits.
 Signal Conditioning of I/O s
• a) Analogue Signals:
•> Temp/flow/press/level etc., to 4 to 20 mA current signals
•> Current to pneumatic pressure for control valve actuation:4-20mA to 3-15psi
•> Pneumatic to current for transmission: 3-15psi to 4-20mA
•> Position Transducers like LVDT for engine shaft movement , alignment etc.,
• b) Digital Signals :
•> Relay inputs/outputs -- potential free contacts
•> Transistor switches -- interface to proximity switches
•> Triac switches -- ckt. Condition, motor control electronics etc.,
• c) DAC / ADC:
•> Analogue to digital and digital to analogue signal conversions in computer
systems for input conditioning and display needs
• d) Opto couplers / Isolators:
•> For Fibre optic cable signal transmission over long distances & signal isolation.
 PLCs Testing & Troubleshooting

• Testing:

•Hardware checks as per assembly diagram. Input /Output wiring checks .

•Power supply checks as per design.Modules power on test.

•Software check by sample program injection: programmer or laptop.

• Troubleshooting:

• Visual Inspection for PCB, circuit damages, connection defects etc.,

• Power supply checks – voltage,frequency, fluctuations etc.,

• Input open, output fuse blow-out checks for no output

• Self diagnostics error indication by LEDs on the front panel.

• Software test by sample program injection by laptop, programmer .

 PLCs in Marine Applications

Technical Functions:
} Main engine interlocks and alarm monitoring
} Boiler operation control
} Generator start up & parrallel run synchronising
} Emergency generator start up & load switch on
} Cargo movement & space monitoring

Vessel Management System :

} UMS area monitoring
} Energy Management
} Maintenance management system
} Inventory control system

Advantages:
• Built-in Redundancy of controls
• Built-in self diagnostics of system
• Fail to Safe system response
 KEY FACTORS – INTRODUCING PLC ON BOARD

• Consider cost benefit : Saving of manpower

Savings in time
Avoid costly human errors

• Implement on full fleet : Uniform across full fleet

Compatible to systems on land
Keep backup systems

• Choice of hardware : Select current models

Ensure upgradability

• Choice of software : Inhouse/External packages

Customisation & Updates
 IMPACT OF NEW TECHNOLOGY
Need for
No Change? Why?
a) Increase profits
• Stay obsolete • Better manpower Deployment/
• Competition ahead Less Human error
• Go out of business • Higher Productivity/ Less waste
• Higher efficiency/ Less downtime
Yes
b) Improve “SHE”
• Tight process control
• Adequate Protection &/ warning
• Eliminate manual routines

“State of Art” in. Can we sustain it?

DEMANDS
Men Machines
• Skill up gradation • Sensitive to environment
• Speed of response • Rapid rate of obsolescence
• Alert eye • Minimal reparability
• Quality of workmanship
SUPPORTS
Proper workplace, Test Equipments, Right tools, Technical information, documentation, Adequate spares
and above all
POSITIVE ATTITUDE
THANK YOU!!
 FULLY DISTRIBUTED PROCESSING

Centralized Strictly Hierarchical

Distributed Hierarchical Distributed Highly Distributed

 FULLY DISTRIBUTED PROCESSING

ROS (Remote Operator Station)

Global Process Bus

PSC (Process Segment Controller)

Local Process Bus

Process
Segment

LOS (Local Operator Station)

DPU (Distributed Process Unit)

 TYPICAL SHIP’S IT NETWORK CONSTRUCTION
Off ship n/w
Satellite/ Telephone Link

Engr’s Term.
Admin. n/w

IBS Firewall
System n/w
Alarm
Navigation General Automation

S Switch
Fire
Radar, ECDIS etc. C&B
S
S Machine Instr. n/w

S S
S S S
 I.T ON BOARD
PURCHASE SYSTEM INVENTORY CONTROL

ITEM CODE

• VENDOR LIST • RECEIPT & CONSUMPTION

• QUOT./TENDER/ENQS. • ITEM LOCATION
• COST/DEL. TIME EVALN. • MIN. STOCK CHECK
• ORDER RELEASE • EOQ LEVEL FEEDBACK
• GUARANTEE/AMC TERMS • CRITICAL SPARES CHECK
• DEL. DOC. FOLLOW UP • CONSUMPTION TREND
• PAYMENTS & FILE CLOSE • PRIORITY CHECK - ORDERS

I.T ADVANTAGES:
• ALTERNATIVE VENDOR EVALUATION ONLINE
• ONLINE INDENT/ORDER TRANSFER TO SHORE OFFICE
• DEL. TIME/PORT OF DEL. DETAILS RECEIVED PROMPTLY
• SHIP/OFFICE/VENDOR CONNECTIVITY IMPROVES PURCHASE
• DUPLICATE/WRONG INDENTING AVOIDED
 I.T FOR ENGINEERING
MTCE SCHEDULE

POLICY TYPE
AREA
• VENDOR • PLANNED
• COMPANY • CONDITION BASED
• STATUTE • BREAKDOWN
M/C CODE

TECH. SPEC. MTCE MANUAL PAST HISTORY

• LIST OF JOBS
• ORIGINAL DESIGN • FAILURES & REMEDIES
• DRGS. & GRAPHS
• MODIFICATIONS • TEMP. REPAIRS
• SPARES LIST
• LIMITATIONS • SPARES SUBSTITUTION
• MAN HOURS

PLUS
DRY DOCK JOBS & OUTSTANDING JOBS LISTED

MTCE BUDGETING
• ANNUAL BUDGET FORECAST
• TILL DATE RUNNING COST
• UPCOMING COST PROJECTION
• DRY DOCK JOB COST
• VARIANCE ANALYSIS