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    Safety PLC

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    ARUNKUMAR M
    This document discusses safety programmable logic controllers (PLCs). It explains that safety PLCs incorporate diagnostic functions to detect internal faults so failures do not cause unsafe situations. They use techniques like micro-pulses and dual output transistors to achieve fail-safe outputs. Safety PLCs are designed per safety standards, certified by organizations, and incorporate self-diagnostics to detect dangerous faults and ensure safe machine operation. While costing more initially, they have lower total lifetime costs than standard PLCs.

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    © All Rights Reserved
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    Safety PLC

    Uploaded by

    ARUNKUMAR M
    66 views11 pages
    This document discusses safety programmable logic controllers (PLCs). It explains that safety PLCs incorporate diagnostic functions to detect internal faults so failures do not cause unsafe situations. They use techniques like micro-pulses and dual output transistors to achieve fail-safe outputs. Safety PLCs are designed per safety standards, certified by organizations, and incorporate self-diagnostics to detect dangerous faults and ensure safe machine operation. While costing more initially, they have lower total lifetime costs than standard PLCs.

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    This document discusses safety programmable logic controllers (PLCs). It explains that safety PLCs incorporate diagnostic functions to detect internal faults so failures do not cause unsafe situations. They use techniques like micro-pulses and dual output transistors to achieve fail-safe outputs. Safety PLCs are designed per safety standards, certified by organizations, and incorporate self-diagnostics to detect dangerous faults and ensure safe machine operation. While costing more initially, they have lower total lifetime costs than standard PLCs.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    66 views11 pages

    Safety PLC

    Uploaded by

    ARUNKUMAR M
    This document discusses safety programmable logic controllers (PLCs). It explains that safety PLCs incorporate diagnostic functions to detect internal faults so failures do not cause unsafe situations. They use techniques like micro-pulses and dual output transistors to achieve fail-safe outputs. Safety PLCs are designed per safety standards, certified by organizations, and incorporate self-diagnostics to detect dangerous faults and ensure safe machine operation. While costing more initially, they have lower total lifetime costs than standard PLCs.

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    EI 8075

    SUBJECT CODE

    FIBRE OPTICS
    TYPE THE SUBJECTAND
    NAME LASER
    HERE INSTRUMENTS (COMMON TO EIE &ICE)

    UNIT NO V

    ADVANCED TOPICS IN AUTOMATIONPLC


    & SCADA

    III VI 5.5 Safety PLC

    EI8651

    LOGIC AND DISTRIBUTED CONTROL


    SYSTEMS (COMMON TO EIE & ICE)
    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    What is a safety PLC?

    ❖ Let ’s try to explain it in a simple way for non -experts. The

    fundamental difference with a general purpose PLC is summed up

    in one word “Diagnosis”. In addition, there are differences in terms

    of internal architecture, software and firmware, and certification for

    applications where compliance with a certain SIL level is required.


    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    ● The safety PLC incorporates many diagnostic functions to

    detect any possible internal fault in the hardware or firmware,

    so that a failure in t he PLC does not cause any “unsafe”

    situation .

    ● These diagnostics reduce the rates of dangerous undetected

    failures and the probability of failures.


    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    Let ’s see with an example what’s “diagnosis” . The first figure


    shows a simplified diagram of a digital output of a general-
    purpose PLC. If the output transistor is short-circuited we have a
    dangerous failure and the valve does not close when ordered by the
    CPU.
    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    What improvements introduces a safety PLC?

    We see it in the second figure.


    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    For detecting short circuit it uses a diagnostic routine by means


    of micro-pulses and monitoring output status. With this it can at
    least give an alarm in case of short circuit.

    To further act on the output in case of failure it uses a second


    transistor in series, with an interlock with the monitoring circuit
    (called “watchdog”) which compares the status of both output
    transistors.
    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    In this way we get a safe output circuit (“fail safe”), fault tolerant from
    the point of view of Safety. To get also Availability redundant architectures
    are used, in this example by paralleling two circuits of the same
    output as shown in the third figure.
    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    There are many diagnostic functions in the safety PLC, both CPU
    and memory as inputs, outputs and communications, and that logically
    carries an additional cost.
    It is important to note that the design of a safety system must consider
    the entire “SIS”, i.e.: the PLC, field devices, electrical supplies, control
    cabinet design, software, etc.
    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    Statistically there are more failures in sensors and actuators than in the PLC.

    Finally, international standards make a classification of the applications


    according to its risk level: SIL-1, SIL-2, SIL-3 and SIL-4 (Safety Integrity
    Level), being part of the risk analysis to be performed by the SIS designer.

    In summary, the fundamental differences of a safety PLC respect to

    general purpose are: 1-Meets design Standards of Safety Systems

    such as IEC61508, NFPA, FM, etc.


    2- It is certified by competent organizations such as TÜV, Exida, etc.
    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    3- Incorporates self-diagnostic routines of all hardware and software to


    detect any dangerous internal fault. If it occurs, it acts leading the
    machine or process to a safe situation. Therefore the dangerous
    undetected rates are lower than in the standard PLC.

    4- The cost of the safety PLC is higher on the initial investment


    (CAPEX) but certainly lower in its total life cycle (OPEX).
    EI 8651
    LOGIC AND DISTRIBUTED CONTROL SYSTEMS (COMMON TO EIE &ICE)

    Video link

    https://www.youtube.com/watch?v=i-X3cDPaBbk

    https://new.siemens.com/global/en/products/automation/topic-
    areas/safety-integrated/factory-automation/offering/simatic-
    safety.html

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