PLCs in Process Control

Applications/Technology Feature Special for June 1989

I&CS

The programmable logic controller (PLC) may have been born in discrete
manufacturing, but has grown with process control.

Although the first PLC -- built by Modicon -- was installed in 1969 in a General
Motors plant, only a few years passed before the technology began working its way
into process control. Batching, in particular, requires sequencing and interlocking
schemes similar to discrete manufacturing, and a PLC can easily replace a batch
control's relays and drum sequencer. A PLC can also substitute for an operator
because it will do the translations between lights and pushbuttons.

A bit of history. Although the Modicon PLC did computerize hard-wired relay logic,
it was not called a computer in part to avoid the image that computers were
complex, unreliable, and maintainable only by engineers. Instead, it was referred
to obliquely as a programmable controller. Recently, the modifier "logic" has crept
into the name to avoid programmable controller and personal computers being
both called PCs.

However named, a PLC is a unique form of computer because it relies on the relay
ladder logic understandable to plant electricians. It also provides predictable,
realtime control through rapid scanning of input/output points, connects directly to
power voltages, is modular for quick repair, and is hardened against the plant
environment.

Modicon PLCs continue to invade the territory of the traditional distributed process
control system (DCS). In kind, DCS people have added more discrete capabilities
to their equipment. Both PLC and DCS vendors offer hardware and software that
permit them to compete for the same process control projects a large gray area of
applications has emerged where either system can be chosen. A systems
engineer can often address a specification written for a DCS and, by substituting a
fast and powerful PLC and MMI interface, develop an attractively priced
configuration meeting application requirements.

Feelings Run Strong

Whether a PLC- or DCS-based process control system is chosen often reflects the
philosophy of the end-user more than the merits of the two approaches. Some
plants and companies are pro DCS, others pro PLC. Even inside a single plant,
proponents of both camps often reside.
Part of the prejudice derives from the fact that particular control equipment has
long been associated with particular processes. For instance, PLCs are often
associated with batching, packaging, and materials handling, DCSs with
continuous flow. But defining batch and continuous processes is difficult.
Elements of both categories seem to be present in all processes. One chemical
company eliminated the argument by defining batch and continuous processes
according to specific ratios of discrete points to analog loops. In any case,
definitions may be irrelevant. A temperature loop in a purely batch process in no
different than a temperature loop in a purely continuous process.

When evaluating Modicon PLCs for process control, systems integrators should
view them as system controllers rather than specialty controllers. Modern PLCs
have full systems capabilities; an entire process having both batch and continuous
elements can be operated and supervised from one platform. Also, the highest
productivity usually results when all automation in a plant is coordinated. For
example, a synthetic textile fibers manufacturer has been able to boost plant output
substantially by using a single PLC based system to control polymer flows,
extrusion, and packaging.

Advances Keep Coming

PLCs have become more important to process control because hardware and
software advances have improved their power, memory, speed, and
programmability. In addition analog, high speed analog, PID, thermocouple, RTD,
and similar modules have been developed for process control and have blurred the
distinctions that formerly existed between the discrete and analog worlds. So too
have new PID blocks and algorithms.

Man-machine interfaces (MMIs), such as those based on personal computers,

workstations, or minicomputers have brought Modicon PLC systems into the
control room. These supervisory computers are becoming faster, more powerful,
and cost effective. When combined with standard process monitoring and control
software interface packages, they provide displays, data gathering, recordkeeping,
loop faceplates, etc., equivalent to a DCS.

Recent developments in "smart I/O" modules such as PID have aided in

decentralizing some control functions, a major requirement in process control. The
independently powered module can be placed in a remote I/O rack and connected
to its own MMI. Even if the PLC fails, the PID module continues to function.

Coming soon from Modicon is a series of products that will permit control system
designers to distribute PLC computing power by integrating a number of small
PLCs and an MMI computer on a peer-to-peer high-speed network. The MMI in
turn could be connected to an MIS network. Such a configuration could leapfrog
"smart I/O" technology by allowing the designer to assign the full power and
flexibility of a PLC CPU -- rather than only an I/O module -- to speed-sensitive
functions at the ends of the link.

At present, PLC systems designers often mimic such a distributed system in a

single PLC by breaking up the control system internally in software and adding an
overall control program to provide a continuous interlock. This effort, however, is
time consuming and not nearly as capable, flexible, or powerful.

It is envisioned that the new distributed Modicon PLC technology will, as an

example, permit batching equipment to be operated by one PLC, a continuous
machine by another, and other processes by a third. All three could link to a host
PLC whose job would be to coordinate the entire system. The MMI in turn could
look transparently at all four PLCs.
Also included on the network might be other PLCs, data concentrators, network
monitors, program load-retrieve-verify terminals, robot cells, and the like.

Adapting PLCs for Process Control

Resistance to using PLCs for a complete process control system historically has
revolved around deficiencies that either no longer exist or shortly will be eliminated.

Computational Power. Because a DCS is minicomputer based, considerable

computational power can be brought to bear. PLC systems, with their ladder logic,
seem less powerful. However, the availability of a variety of custom function
blocks, analog-type I/O modules, and co-processors provides all of the power
necessary for many applications.

A new gold ore refining facility confirms that a PLC is sufficiently powerful for a
complex process control system. Plant control is centralized in a pair of redundant
Modicon 984B PLCs handling 30 PID loops, 450 analog points, and 1000 discrete
points. Serving as the MMI are several personal computers linked to the PLC.
The computers include realtime co-processor I/O handlers to poll PLC registers
and to pseudo-multitask and are loaded with a process control software package.
About 11 Mbytes of hard disk storage retain some 100 display screens.

According to the plant's metallurgist, most gold plants use either a DCS or
redundant PLCs with a minicomputer MMI. In this application, the PLC performs
all motor control, PID algorithms, and mathematical computations and was only
half the cost of a DCS.

Downstream cost advantages for the PLC-based system also were claimed by the
mining company. These included maintenance and process changes by plant
electricians rather than engineers, high reliability through hot-standby redundancy,
and ability to shift stored process data from the MMI software into a low cost
statistical package.
Speed. Because it functions by scanning every I/O point, a PLC may respond
more slowly than a computer. On the other hand, a PLC is as ordered and
predictable as a hard-wired relay panel. When an operator pushes a button, the
response time is known and constant. Response does not vary from microseconds
to seconds as it might with a computer. When response is predictable, a control
system can be engineered with greater confidence. PLCs operating speeds have
been increasing, and the development of high speed analog modules, smart I/O,
and distributed PLCs will increase system speed further. Additionally, faster
networks and computers will speed up MMIs.

Networking Capabilities. New PLC communications products will enhance this

capability. Further, because many of the advances relate to the MAP standard,
compatibility between various vendors' equipment should increase.
Compatibility promotes a wider range of choices for control system designer and
makes for potentially lower costs downstream because end users are not locked
into one vendor.

Taking Advantage of PLC Strong Points

Relative to other control equipment, PLCs offer unique advantages.

Flexibility. The PLC is a general purpose machine that is usually programmed

from scratch for a process control task. It is not pre-loaded with a dedicated
program of loops and screens and then configured to an application. Compared to
configuring, a PLC-based process control system allows a more customized final
product and, once programmed, the end-user can easily modify the program
himself. Also, the end-user can initially program the PLC, or he can have a
systems integrator do it. The possibility exists for using packaged MMI software to
prepare standard PLC process control loops and screens that could shorten the
time to program the system, while still retaining end-user flexibility.

Maintenance by Electricians. PLCs typically are maintained by electricians,

while computers are maintained by engineers and programmers. Many plants
don't have personnel on staff capable of programming or troubleshooting a
computer and must depend on vendor personnel. Additionally, complaints are
often heard among controls engineers that they can never quite turn computer-
based control systems over to the plant. With PLCs, plant operating personnel
seldom require engineering assistance after start-up.

Connectivity. PLC-based process control systems offer superior communications

with external devices such as drives, temperature controls, islands of automation,
etc. A PLC has numerous ports that can be dedicated to third-party devices, and
these ports provide an easy path for information flow in and out of the control
system. Connections can also be made by electricians. In terms of drives, PLCs
now are fast enough to be part of the control loop, not just the supervisor.

Ruggedness and Reliability. PLCs don't need to be housed in air-conditioned

environments, have battery-backed memory for storage of important process data,
and offer hot-standby configurations of redundant CPUs and I/O cabling.