PLC and SCADA

Introduction

Rajeevan.A (MIET, MSc, BEng)

Faculty of Engineering and Construction
ICBT Campus
Subject Introduction
• 10 Credit Module
• 20 – 30 Hours Lecture
• 2 practical's
Aim
• To develop a detailed understanding of Programmable Logic
Controllers and their application to industrial control. To
develop the ability to understand and apply Supervisory
Control and Data Acquisition Systems (SCADA) to a wide
spectrum of industrial problems.
Learning Outcome
• Learning Outcomes On completion of the module students should
be able to:

1. Design and implement control schemes using pneumatic/electro-

pneumatic hardware.

2. Understand PLC architecture and operation.

3. Develop PLC software to solve a range of industrial problems.

4. Understand the basic structure of SCADA systems and

select/configure appropriate SCADA systems for a range of problems.

5. Undertake a redundancy and risk assessment

Introduction to Module
• The lessons presented in this module adopt a dual format:
1. a conventional format – written notes covering the particular
topic under discussion and

2. a format based upon a PLC software simulation package –

LogixPro.
Learning Outcome
• Introduction to PLC.

• Review of combination and sequential logic.

• Basic Ladder diagram.

History
• Control engineering has evolved over time. In the past humans
were the main method for controlling a system. More recently
electricity has been used for control and early electrical control
was based on relays.
• Relays allow power to be switched on and off without a
mechanical switch. It is common to use relays to make simple
logical control decisions.
• The development of low cost computer has brought the most
recent revolution, the Programmable Logic Controller (PLC). The
advent of the PLC began in the 1970s, and has become the most
common choice for manufacturing controls
Advantage of PLC in industry
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other systems quickly
and easily.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce
downtime.
• Reliable components make these likely to operate for years
before failure.
PLC (Programmable Logic
Controller)
• Programmable Logic Controllers (PLCs) are basically
microprocessor devices that are used throughout industry to
control plant operations.
• In addition, although there are many different types of PLC,
the generic structure is similar and consists of three main
components.
• Power Supply
• A central processing unit
• Input/output Module
PLC Basic Block Diagram
PLC Basic Operation - Example
PLC Manufactures
• Allen-Bradley,
• Mitsubishi,
• Siemens,
• Omron,
• Telemechanique,
PLC Selection to an application
• The physical size of the PLC and its functionality.

• The type and number of I/O modules.

• There are numerous types of I/O modules available ranging from
simple digital modules to intelligent function modules which in
some cases have their own dedicated processors.
Types of PLC
• In terms of physical look, there are three main types of PLC
• Brick
Types of PLC
• Modular
Types of PLC
• Medium sized PLC
PLC Programming
• Ladder Logic
• Statement List
• Graphical Format
Activity
• Think of a practical application of PLC, and explain the
operation.
• Identify which type of PLC can be select for your application.
Combinational logic abstraction
• Combinational logic abstraction
• Logic gate abstractions
• Logic simplification
• Boolean algebra
• K-Map
Sequential Logic abstraction
• Sequential Logic
• Devices
• Latches
• Flip-Flops
• Timers
Simple relay to ladder
• ladder logic has
been developed
to mimic relay logic.
Simple relay to ladder
Basic Ladder
• Ladder logic Input
Basic Ladder
• Ladder logic output
Basic Ladder
• Ladder logic output
Question
• Try to develop (without looking at the solution) a relay based
controller that will allow three switches in a room to control a
single light.
Logic gates and ladders
• AND Logic

• OR Logic
Logic gates and ladders
• Complex logic gates
Boolean logic design
• Design 2-4 Multiplexer using Ladder logic

• Develop a program that will cause output D to go true when

switch A and switch B are closed or when switch C is closed.

• Develop a program that will cause output D to be on when

push button A is on, or either B or C are on.
Instruction List (Mnemonic
program)
Mnemonic program
Sequential function chart
• The term sequential function chart (SFC) is used for a pictorial
representation of a system’s operation to show the sequence
of events involved in its operation. SFC charts have the
following elements:
• The operation is described by a number of separate sequentially
connected states or steps that are represented by rectangular
boxes, each representing a particular state of the system being
controlled.
Light Flash
Structured text program