1.

List four distinct advantages that PLCs offer over conventional relay-based control
systems.
1. PLCs are programmbale
2. Many control relays can be replaced by software, which means less hardware
failure.
3. It is easier to make changes in software than in hardware.
4. Special functions such as time delay actions, counters are easy to produce in
software.
5. Reliability is more.
6. There is almost no task limit to tasks for which PLCs can be used.
2. Define PLC.
A programmable logic controller (PLC) is a small, modular solid state computer with
customized instructions for performing a particular task. PLCs, which are used in
industrial control systems (ICS) for a wide variety of industries, have largely replaced
mechanical relays, drum sequencers and cam timers.

3. When is the output of a programmed timer energized?

Timers are the instructions that give required time delay to on or off a specific task of
an event. It means after a certain time delay the timer times out.
4. Under what condition is a ladder logic rung said to have logic continuity?

A ladder logic rung is said to have logical continuity only when there is a continuous
path from one side of the power rail to the other. Logic continuity can be achieved by
true conditional instructions in a rung.
5. Draw the logic gates symbol for AND gate and NAND gate in function block diagram.

NAND

6. What do you mean by instruction list?

IL is a low-level programming language. It is very effective for small, simple
applications or for optimizing parts of an application. Instructions always relate to the
current result and the operator indicates the operation that must be made between the
current value and the operand. The result of the operation is stored again in the current
result.
7. What do you mean by Local Control Unit?
LCU is the smallest collection of hardware in the distributed control system that
performs closed loop control. It takes inputs from process- measuring devices and
commands from the operator and computes the control outputs needed to make the
 process follow the commands.

8. Give some application of DCS.

 Chemical plants
 Petrochemical (oil) and refineries
 Pulp and paper mills (see also: quality control system QCS)
 Boiler controls and power plant systems
 Nuclear power plants
 Water management systems
 Water treatment plants
 Food and food processing
 Agrochemical and fertilizer

 Metal and mines

9. Assess the need for cloud based automation.
Cloud automation is a broad term that refers to the processes and tools an organization
uses to reduce the manual efforts associated with provisioning and managing cloud
computing workloads. IT teams can apply cloud automation to private, public and
hybrid cloud environments.

10. List the features of plant wide control.

The plantwide control deals with unit-to-unit interactions through the choice of
measured and manipulated variables in each unit and the selection of a control strategy
—namely, how to pair controlled and manipulated variables in individual loops, where
to use multiloop controllers, where to use multivariable controllers such as MPC, and so
on.

Part - B ( 5 x 13 = 65 marks )
11 a. Describe the typical parts of a programmable logic controller with neat sketch. (13
 OR
b. Explain the basic function of discrete AC input module involved in PLC. (13
12 a. Write a ladder program using Up Counter to turn the red pilot light on and the green pilot light (13
off after an accumulated count of 7.
The operation of the program can be summarized as follows:
1. Operating pushbutton PB1 provides the off-to-on transition pulses that are counted by
the counter.
2. The preset value of the counter is set for 7.
3. Each false – to - true transition of rung 1 increases the counter’s accumulated value by
1.
4. After 7 pulses, or counts, when the preset counter value equals the accumulated counter
value, output DN is energized.
5. As a result, rung 2 becomes true and energizes output O:2/0 to switch the red pilot light
on.
6. At the same time, rung 3 becomes false and deenergizes output O:2/1 to switch the
green pilot light off.
7. The counter is reset by closing pushbutton PB2, which makes rung 4 true and resets the
accumulated count to zero.
 8. Counting can resume when rung 4 goes false again.

OR
b. Write a ladder program that uses an on-delay timer with timing diagram. The operation of the (13
program can be summarized as follows:
1. The timer is activated by input switch A.
2. The preset time for this timer is 10 s, at which time output D will be energized.
3. When input switch is A is closed, the timer becomes true and the timer begins
counting and counts until the accumulated time equals the preset value; the output D is
then energized.
4. If the switch is opened before the timer is timed out, the accumulated time is
automatically reset to 0.

5. This timer configuration is termed nonretentive because any loss of continuity to the
timer causes the timer instruction to reset.
6. This timing operation is that of an on-delay timer because output D is switched on 10 s
after the switch has been actuated from the off to the on position.
13 a. (i) Write an IL program to turn off a conveyor belt on a production line after 10 parts (10
have been produced. Assume the following:
1. Output bit Q124.5 = 0, turns off the conveyor belt;
2. Input I124.6 changes from 0 to 1 and then back to 0 each time a production
part is rejected;
3. Input I124.7 changes from 0 to 1 and then back to 0 each time a new part is
produced;
4. A NO pushbutton connected to input I124.2 is used to set the production
count to 10;
5. A NO pushbutton connected to input I124.3 is used to reset the counter to
zero and to stop the conveyor belt. Use counter number 4 in the IL program.

(ii) Write an IL program to subtract a 32-bit floating point number in word MD70 from a (3)
32-bit floating-point number in word MD74 and then divide the result by 10. Store the
final result in word MD78.

OR
 b. (i) Write a FBD program to start a pump that will fill a process tank with fluid until a (7)
high level is reached in the tank. Assume that a normally opened fill tank pushbutton
is wired to a discrete input module at I124.4 and a normally closed tank high-level
switch is connected to input point I124.5 on a Siemens CPU314IFM.Also assume that
the pump start relay is connected to output Q124.0 on the same Siemens PLC.

(ii) Write a FBD program to control an electric motor. Assume that a NO start pushbutton (6)
is wired to an input point I124.0 and a NC stop pushbutton is wired to input I124.5 of
a Siemens CPU314IFM. Also assume that output Q124.1 of the Siemens PLC will
control a motor start relay, and there is an auxiliary motor start contact (NO)
connected to the PLC input I124.1.

14 a. Describe the hierarchy of DCS with neat diagram. (13

Distributed Control System (DCS) Architecture
Introduction: The biggest disadvantages of the centralized computer control architecture is that the
central processing unit (CPU) represents a single point process if it is lost. Another problem with
these computer-based systems has been that the software required to implement all of the functions
is extremely complex, and requires a priesthood of computer experts to develop the system. The
centralized system is limited in its capability to accommodate change and expansion. The
disadvantages of hybrid system architecture has its deficiencies. It is composed of many different
subsystems. Starting them up and making them work as an integrated whole is no less difficult task.
The hybrid approach also is functionality limited compared to the central computer based system.
The limitation of centralized computer system and hybrid system introduced distributed control
system. The devices in this (DCS) architecture are grouped into three categories; those that interface
directly to the process to be controlled or monitored, those that perform high-level human interfacing
and computing functions, and those that provide the means of communication between the other
devices. A brief definition of each device is given below:
Local Control Unit (LCU): The smallest collection of hardware in the system that can do closed loop
control. The LCU interfaces directly to process.
Low Level Human Interface (LLHI): A device that allows the operator or instrument engineer to
 interact with LCU (eg: to change set points, control modes, control configurations, or tuning
parameters)
using a direct connection. LLHIs can also interface directly to the process. Operator-oriented hardware
at this level is called Low Level Operator Interface (LLOI); instrument engineer–oriented hardware is
called
a Low Level Engineering Interface (LLEI).
Data Input / Output Unit (DI/OU): A device that interfaces to the process alone for the purpose of
acquiring or outputting data. It performs no control functions.
High Level Human Interfaces (HLHI): A collection of hardware that performs functions similar
to the LLHI but with increased capability and user friendliness. It interfaces to other devices only over
the shared communication facilities. Operated-oriented hardware at this level is called a High Level
Operator Interface (HLOI); instrument engineer-oriented hardware is called a High Level Engineering
Interface (HLEI).
High Level Computing Device (HLCD): A collection of microprocessor based hardware that performs
plant management functions traditionally performed by a plant computer. It interfaces to other
devices only over the shared communication facilities.

Computer Interface Device (CID): A collection of hardware that allows an external general purpose
computer to interact with devices in DCS using shared communication facilities.
Shared Communication Facilities: One or more levels of communication hardware and
associated software that allow the sharing of data among all devices in DCS. Shared communication
facilities do not include dedicated communication channels between hardware elements within the
device

OR
b. Discuss about general building blocks of LCU with neat diagram. (13
1. Local Control Unit (LCU) Architecture
The LCU is the smallest collection of hardware in the DCS that performs closed loop control.
That is, it takes inputs from process-measuring devices and commands from operator and
 computes the control outputs needed to make the process follow the command. It then sends
control output to actuators, drives valves and other mechanical devices that regulate the flows,
temperatures, pressures, and other variables to be controlled in the plant. An LCU malfunction
can cause a condition that is hazardous to both people and equipment. Its proper design is
critical to the safe and efficient operation of the plant.
Basic Elements of a Microprocessor-Based Controller

The basic elements of a LCU are shown in figure. The microprocessor along with the
associated clock comprises the central processing unit (CPU) of the controller. ROM is used
for permanent storage of controller programs. RAM is used for temporary storage of
information. Depending upon the type of microprocessor used, RAM and ROM can be
located on the microprocessor chip or on separate memory chip. The LCU must have I/O
circuitry so that it can communicate with the external world by reading in, or receiving analog
and digital data as well as sending similar signals out. The CPU communicates with the other
elements in the LCU over an internal shared bus that transmits addressing, data control and
status information in addition to the data.
The controller structure shown in figure is the minimum required to perform basic control
functions. The control algorithms could be coded in assembly language and loaded into ROM.
After the controller was turned on, it would read inputs, execute the control algorithms, and
generate control inputs in a fixed cycle indefinitely. However, because the situation is not this
simple in industrial applications, the controller structure shown in figure must be enhanced to
include the following:
 Flexibility of changing control configuration.
 Ability to use the controller without being computer expert.
 Ability to bypass the controller in case it fails so that the process still can be controlled
manually.
Ability of the LCU to communicate with other LCUs and other elements in the system

15 a. Illustrate the applications of PLC with case studies. (13

Thermal power plant-case studies
OR
b. Discuss in detail about networked control system with neat diagram. (13
• In many complex systems, communication networks are employed to exchange
information between spatially distributed system components
• Dynamical systems are becoming inherently more networked
• Pros: efficient monitoring, distributed computation, low cost, ease of use
• Cons: vulnerability, networked-induced delays and perturbations, attacks
• Examples: power-grids, transportation networks, water networks, vehicles, aircrafts...
• NCSs control and monitor most Cyber-Physical Systems (CPS)
• NCS: control system that closes its control loops
through a network
• Exchange of information between plant and controller via a network
• The u’s and the y’s are sent to controllers through a comm. Network

• NCSs: the so-called 3rd Gen of Control Systems

• What are the first two generations of control systems?
• Advantages: modularity, flexibility and simplicity of implementation and reduced
system wiring
• All modern cars have NCSs
• Network effect can be modeled as perturbation or time-delay to the exchanged signals
• One node can only use the shared medium at any given time
Design Objectives:
1. Develop a system that efficiently uses the finite bus capacity while maintaining
reasonable closed-loop control system performance.
2. The addition of network to the system will improve system reliability, reduce weight,
space, power
and wiring requirements. Nevertheless, there are constraints that somewhat limits its
applications. Hence, satisfying these physical constraints is another NCS objective
Applications:

 Manufacturing plants, automobiles, air conditioning/cooling systems, elevators

 Building automation, medical equipment, remote surgery, mobile sensor networks
 Robotics, UAVs, drones
 Transportation systems, power systems, communication networks
 Economic systems, spacecraft dynamics
 ..And many more...

Limitations
• Modern control systems are increasingly adopting the networked control framework
• Another NCS objective is design systems with improved QoS
• QoS of the network includes the network’s fairness, tolerance to packet losses, etc...
• Insertion of a communication network in the feedback control loop makes the analysis
and design of an NCS more complex
• Hence, there are disadvantages and challenges that come from adopting the networked
control configuration
 • Important issues that an NCS designers address are: network’s fairness, stability,
delays, and error analysis
Crucial design challenges: network-induced perturbations, attacks, and time-delays

Part - C ( 1 x 15 = 15 marks )
16 a. A conveyor is supposed to have exactly 45 parts on it. Three indicating (15
lights used to indicate the conveyor count status: less than 45, yellow;
exactly 45, green: and more than 45, red. The count of parts on the
conveyor is set at 45 each morning by an actual count of parts. There
are two sensors on the conveyor. One is actuated by parts entering the
conveyor, and the other is actuated by parts leaving. Develop a PLC
program using compare functions.
 OR
b. Write a FBD program to turn off a conveyor belt on a production line after 50 parts have (15
been produced. Assume the following for the control program:
1. Output bit Q124.5 = 0, turns off the conveyor belt;
2. Input I124.1 is set to 1 each time a production part is rejected;
3. Input I124.2 is set to 1 each time a new part is produced;
4. A normally open (NO) pushbutton connected to input I124.6 is used to set the
production count to 50, and
5. A NO pushbutton connected to input I124.7 is used to reset the counter to zero and
to stop the conveyor belt.