PROGRAMMABLE LOGIC

CONTROLLER (PLC)

BY . ER.ARABINDA MOHANTY

INTRODUCTION
The first Programmable Logic Controller (PLC) was developed by a
group of engineers at General Motors in 1968, when the company were
looking for an alternative to replace complex relay control systems.

The new control system had to meet the following requirements:

• Simple programming.

• Program changes without system intervention

(no internal rewiring)

• Smaller, cheaper and more reliable than corresponding relay control

systems.

• Simple, low cost maintenance.

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 DEFINATION
• A Programmable Logic controller or PLC is a microprcessor based device ;
which is capable of storing instructions to implement control function
such as
• logic
• Sequencing
• timing
• counting
• Arithmetic
• data manipulation
• and communication ……..
……. to control industrial machines and processes .

BASIC BLOCK DIAGRAM

Programming unit

CPU
Input Output
module Memory module

Power supply

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BASIC COMPONENTS OF PLC

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BASIC BLOCK DIAGRAM

SENSOR

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 ACTUATORS

DISCRETE INPUT

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 ANALOG INPUT

DISCRETE OUTPUT

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ANALOG OUTPUT

CPU

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 PLC PROGRAMMING LANGUAGES :-

• Ladder Diagram ( LD)

• Function Block Diagram(FBD)
• Instruction list(IL)
• Sequential Function Chart(SFC)

PROGRAMMING

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FUNCTION BLOCK DIAGRAM

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PLC SCAN

PLC BASICS

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BASIC PLC OPERATION

PLC VS. RELAY

PROBLEMS WITH RELAY

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 PLC

ADVANTAGES OF PLC
• Flexibility: One single Programmable Logic Controller can easily run many machines.

• Correcting Errors: In old days, with wired relay-type panels, any program alterations required time for
rewiring of panels and devices. With PLC control any change in circuit design or sequence is as simple as retyping
the logic. Correcting errors in PLC is extremely short and cost effective.
•
• Space Efficient: Today's Programmable Logic Control memory is getting bigger and bigger this means that
we can generate more and more contacts, coils, timers, sequencers, counters and so on. We can have thousands
of contact timers and counters in a single PLC. Imagine what it would be like to have so many things in one panel.

• Low Cost: Prices of Programmable Logic Controllers vary from few hundreds to few thousands. This is nothing
compared to the prices of the contact and coils and timers that you would pay to match the same things. Add to
that the installation cost, the shipping cost and so on.

• Testing: A Programmable Logic Control program can be tested and evaluated in a lab. The program can be
tested, validated and corrected saving very valuable time.

• Visual observation: When running a PLC program a visual operation can be seen on the screen.
Hence troubleshooting a circuit is really quick, easy and simple.

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 Auto Control Loop

• Total air control

• Super / Reheat temp. control
• Mill out temperature control
• Hot well / heater / de-aerator level control
• Drum level control
• Furnace draft control

Interlock & Protections

• Interlock & protections are used for safe
startup / operation / shutdown / trip of any
equipment or auxiliaries. E.g.
• CW Pump, ID fan, FD fan, BFP, CEP, Mill, PA fan
• Heaters
• Valves & Drains

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 Boiler Control
• Burner Management System
• Secondary air damper control
• Soot blower control
• Hp / Lp Bypass
• Bag Filter System

Turbine Control System

• Turbine Governing System
• Turbine protection
• Automatic Turbine run up system
• Turbine stress control
• LP Bypass
• Sequence controls for turbine driven BFP
• Generator Aux. monitoring

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