Engineering Encyclopedia

Saudi Aramco DeskTop Standards

PROGRAMMABLE LOGIC CONTROLLER (PLC):

PLC SYSTEM OVERVIEW AND FUNCTIONS OF
BASIC PLC COMPONENTS

Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.

Chapter : Process Instrumentation For additional information on this subject, contact

File Reference: PCI-113.01 PEDD Coordinator on 874-6556
Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Section Page

INTRODUCTION............................................................................................................ 3
Course Introduction................................................................................................... 3
Module Introduction .................................................................................................. 3
PROGRAMMABLE LOGIC CONTROLLER SYSTEM: PURPOSE,
EVOLUTION, APPLICATIONS, AND SCOPING DOCUMENTS.................................... 4
Purpose of a PLC System......................................................................................... 4
Evolution of Control Systems .................................................................................... 4
Hard-Wired Control Systems ............................................................................... 5
Solid State Controls............................................................................................. 5
Programmable Logic Controller (PLC)................................................................. 6
Vendors Systems Used in Saudi Aramco ............................................................ 8
Applications of a PLC System................................................................................... 8
H2S/LEL Gas Monitor .......................................................................................... 9
Machinery Protection System .............................................................................. 9
Gas Dehydrators ............................................................................................... 10
Scoping Documents of a PLC System .................................................................... 11
Operational Requirements................................................................................. 12
Piping and Instrumentation Diagram (P&ID)...................................................... 12
Binary Logic Diagram ........................................................................................ 14
Cause and Effect Chart ..................................................................................... 15
FUNCTIONS OF BASIC PLC COMPONENTS ............................................................ 17
Overall PLC Operation............................................................................................ 17
Input Interface......................................................................................................... 20
Output Interface ...................................................................................................... 20
Central Processing Unit .......................................................................................... 21
Processor .......................................................................................................... 21
Memory ............................................................................................................. 21
Power Supply .................................................................................................... 22
Programming Terminal ........................................................................................... 22
Programming Software ........................................................................................... 23
SUMMARY................................................................................................................... 24
GLOSSARY ................................................................................................................. 25
ADDENDUM: 34-SAMSS-830, SECTION 10: DOCUMENTATION ........................... 29

Saudi Aramco DeskTop Standards i

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

LIST OF FIGURES

Figure 1. Machinery Protection System....................................................................... 10

Figure 2. Batch Mixing System.................................................................................... 13
Figure 3. Binary Logic Diagram ................................................................................... 14
Figure 4. Example Cause and Effect Chart for Documentation Of Shutdown
Requirements ......................................................................................... 16
Figure 5. PLC Operational Relationships .................................................................... 18
Figure 6. PLC System Block Diagram ......................................................................... 19

Saudi Aramco DeskTop Standards ii

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

INTRODUCTION

Course Introduction

The purpose of this course is to provide the information and

procedures related to the use of Programmable Logic
Controllers (PLC) in the various engineering applications in
Saudi Aramco. The applications of the Programmable Logic
Controller in engineering is increasing quite rapidly. It is
important that all engineering personnel have an understanding
of the terminology and applications related to Programmable
Logic Controller systems. The effective and efficient operation
of the processing function in Saudi Aramco is influenced by the
applications of Programmable Logic Controller systems.

The course provides learning experiences in the areas of:

• PLC project scoping documents

• Interpreting PLC system drawings

• Selecting PLC input and output interfaces

• Selecting a PLC processor

• Selecting a PLC power supply

• Programming a Programmable Logic Controller

• PLC system evaluation process

Module Introduction

This module presents the basic terminology related to

Programmable Logic Controller systems. The purpose of the
PLC system and common applications of the PLC system are
discussed. The seven basic PLC components are described,
and the interrelationships of the components are explained.

Module 113.01 is basic to the understanding of the other course

modules.

Saudi Aramco DeskTop Standards 3

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

PROGRAMMABLE LOGIC CONTROLLER SYSTEM: PURPOSE,

EVOLUTION, APPLICATIONS, AND SCOPING DOCUMENTS

Purpose of a PLC System

The purpose of a Programmable Logic Controller (PLC) system

is to provide reliable, efficient, expandable, and economical
control for industrial control systems.

The PLC system has been successfully applied in every

segment of industry, including power plants, chemical and
petrochemical plants, and refineries.

In order to understand the use of the PLC system as the control

device of choice for many industrial processes, the following
topics will be discussed:

• The evolution of control systems

• The applications of a PLC system

• Scoping documentation

Evolution of Control Systems

Historically, industrial control system development can be

traced through the following:

• Hard-wired control systems

• Solid state control systems

• Programmable Logic Controller systems

Saudi Aramco DeskTop Standards 4

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Hard-Wired
Control Systems
Early industrial control systems were non-electric. The control
systems used pneumatic, hydraulic, or purely mechanical
components. Relays were used in later systems to assist in the
control functions.

As technology changed, control systems used

electromechanical components such as the power relay and the
control relay, electropneumatic timers, electric timers and
counters, cam cycle timers, and drum program timers. Because
these components were hard-wired devices, it was a major task
to rewire a control panel when control requirements changed.
In addition to the work required to rewire control panels,
electromechanical devices are subject to wear, contact welding,
solenoid burnout, and short circuiting.

Hard-wired control panels are expensive to install, to test, and

to troubleshoot. When control requirements are changed, such
as for a process change in a refinery, a completely new control
panel must be designed and purchased to replace the existing
panel.

Solid State
Controls
The rapid development of solid state electronics from the
transistor to the integrated circuits in 1958 changed and
continues to change the approach and techniques used for
control of industrial processes. Solid state printed circuit boards
containing integrated circuits and transistors replaced
electropneumatic timers and counters and the relays that are
used for logic functions. These solid state replacements
reduced the number of relays and electromechanical
components, but they did not eliminate the requirements for
many interconnecting wires and the temperature-controlled
environments required for the solid state devices. The control
panel size was reduced but the individual circuit cards,
containing the solid state logic circuits, were still interconnected
with wires.

Saudi Aramco DeskTop Standards 5

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Programmable
Logic Controller
(PLC)
In the late 1960's and the early 1970's, computers were being
used for data processing functions. The computers required
restricted temperature, voltage, and humidity specifications.
The computers were not designed to work in the processing
plant environment.

In 1970, a major United States automobile manufacturer

recognized the weakness with the existing electromechanical
control systems, and it developed a set of specifications for a
computer-like system that would provide flexibility for the control
systems used to manufacture automobiles. The original
specifications included the following requirements:

• A computer-controlled system that is easily programmed

and reprogrammed in the plant.

• A programming language that is easily understood by the

plant electrical and plant maintenance personnel.

• A control system that is able to function in a processing

plant environment. The plant environment, in this context,
refers to environmental specifications of 0 to 60°C and 5 to
95% relative humidity.

• A control system that is highly reliable.

• A control system that has the ability to communicate with

other computers.

• A control system that can handle digital input and output

signals. (Analog signals were not considered at this time.)

• A control system that is physically small.

Basically, the design specifications were for a computer control

system that would operate in the plant environment without the
restrictions that existed for the data processing computer
systems that existed at that time.

Saudi Aramco DeskTop Standards 6

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

From these specifications, the first Programmable Logic

Controller system evolved. The early PLCs could be
programmed, and the program could be altered with a
programming device to handle production changes without
rewiring the system components. Because the PLC system
was easier to maintain than the electromechanical control
systems, greater reliability and reduced down time was
provided. PLCs proved to be effective relay replacers, and they
met or exceeded the criteria set by the automotive industry.

As electronic technology has evolved, the PLC system

capabilities have also evolved. Today, the PLC system
contains extensive communication capabilities, and it has the
ability to perform advanced programmed instructions.

The PLC system represents a rapidly maturing product. The

PLC system capability can be used for the control of industrial
systems ranging from on/off control of compressors or pumps to
distributed control systems. PLC systems are selected as
control systems for the following reasons:

• Cost effectiveness. One of the basic reasons for

developing the PLC system was to reduce the installed
cost of the hard-wired and solid state control systems.

• Versatility. The multifunctionality of the PLC system

provides the ability to combine digital and analog logic
within the same control device.

• Flexibility. The system operation may be changed by

adding additional prewired units and/or by changing the
user program control logic rather than by making physical
wiring changes.

• Expandability. The modular design of the PLC system

allows for the expansion of both the system memory and
the number of devices to be controlled.

• Reliability and Longevity. The solid state design of the

PLC system provides for maximum reliability and long life.

Saudi Aramco DeskTop Standards 7

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

• Computer capabilities. The PLC system, as an industrial

computer, provides for the collection and processing of
data and for the communication with other PLC systems,
and it can diagnose and indicate operational problems.

• Troubleshooting capabilities. The PLC system, with its

ladder-type language and CRT monitoring, provides
enhanced system troubleshooting capabilities for the
engineer and the technician.

Vendors Systems
Used in Saudi
Aramco
The PLC systems currently used within the Saudi Aramco
facilities are manufactured by the following vendors:

• Allen-Bradley

• Modicon

• Texas Instrument (Siemens)

• Honeywell

This course uses the Allen-Bradley PLC-5 processor, the 1771

series Input/Output structure, and associated components for
discussions and examples.

Applications of a PLC System

Some of the areas that Saudi Aramco uses PLC systems are as
follows:

• H2S/LEL Gas Monitor

• Machinery Protection System

• Gas Dehydrators

• Air Compressor Control

Saudi Aramco DeskTop Standards 8

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

H2S/LEL Gas
Monitor

The H2S/LEL gas monitor system used in Aramco Gas Plants

employs smart gas sensors to monitor H2S. The smart gas
sensors provide a 0-20 mA dc analog signal representing the
H2S concentration. The signal is used as an input to the PLC
system. The PLC program monitors the analog signals
representing gas concentration, and it applies limit tests on the
analog values to provide Low, Low-Low, High, and High-High
alarms.

The PLC system uses analog input modules to monitor the gas
concentration, and it uses digital output modules to interface
with the annunciation systems.

Machinery
Protection System
Figure 1 is a simplified representation of Drawing #422-P&I
Sheet 3. Figure 1 illustrates a system that includes machinery
protection. The system is used to transfer material from the
product mixing tank (T-1) to the product storage tank (T-2). The
PLC controls and protects the pump (P-1) and the associated
valves by monitoring various process variables.

In order to protect the pump, the PLC monitors the following

process variables:

• pump bearing temperature (TSH-2)

• discharge line pressure (PSH-3 and PSHH-3)
• product mixing tank level (LSL-1)

If the pump bearing temperature reaches the maximum limit,

switch TSH-2 will open. This is monitored by the PLC and the
PLC program will stop the pump.

If the pump discharge line becomes plugged, pressure switch

PSHH-3 will close. If a line break occurs in the pump discharge
line, pressure switch PSH-3 will open. The PLC monitors
PSH-3 and PSHH-3 contact operation and will stop the pump
when there is either a line break or the line becomes plugged.

Saudi Aramco DeskTop Standards 9

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

If the product mixing tank level drops to empty, the PLC will
activate switch LSL-1 to OPEN. This action will stop the pump
and prevent cavitation.

PROGRAMMABLE LOGIC CONTROLLER

DIGITAL INPUTS AND OUTPUTS

PRODUCT MIXING
TANK T-1 LSH
4

LSL PSHH
1 3

ZS1/O PSH
3

S FV1 PRODUCT
TSH STORAGE
2 TANK T-2
S ZS2/O

FV2
M
P-1

Figure 1. Machinery Protection System

Gas Dehydrators
PLC systems are used to control the drying and regenerating
cycles for the gas dehydrators at gas plants. This application
uses digital input and digital output signals to operate the drying
and regeneration cycles of the dehydrators. The PLC system
includes timing and sequencing functions combined with valve
interlocks to alternately use one dehydrator for removing
moisture while regenerating the second dehydrator.
Periodically, the cycle is reversed: The second dehydrator is
used for drying, and the first dehydrator is regenerated.

Saudi Aramco DeskTop Standards 10

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Scoping Documents of a PLC System

The implementation of a PLC system project involves many

steps that concern organization and order. Effective scoping
documentation is essential to the implementation of the steps.
Scoping documentation is defined as an orderly collection of
recorded information concerning the operation of a control
system and the hardware and software components of the
control system.

Scoping documents are a working tool. If the documentation is

created and kept current through the design of the project, it
will:

• Provide design information.

• Provide a means to communicate information.

• Serve as training material.

The responsibility for documentation involves both the buyer

(Saudi Aramco) and the supplier (vendor) of the PLC system.
Saudi Aramco Materials System Specification 34-SAMSS-830,
Section 10, DOCUMENTATION defines the vendor’s
responsibility for PLC system documentation. Section 10 is
reproduced in the Addendum. The required vendor-supplied
documentation is listed in Section 10.1. The following types of
scoping documentation are required by Saudi Aramco for a PLC
project:

• Operational Requirements

• Piping and Instrumentation Diagrams (P&IDs)

• Binary Logic Diagrams

• Cause and Effect Diagrams

Saudi Aramco DeskTop Standards 11

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Operational
Requirements
The project starts with a description of the process to be
controlled and the process operational requirements. The
description should provide the following information:

• A statement of the control tasks.

• A description of the design task philosophy to be used to

achieve the control tasks. The design task philosophy
should define the functions of the major hardware and
software components of the system.

• The objectives that must be achieved. The objectives allow

the measurement of the control implementation.

Piping and
Instrumentation
Diagram (P&ID)
The P&ID is an engineering document used to describe the
process to be controlled and to designate instruments and
instrumentation systems to be used for measurement and
control of the system. In order to promote uniformity, a
standard is used to reference instrumentation for a control
system. The reference used by Saudi Aramco is the SAES-J-
004: Instrument Symbols and Identification.

Figure 2 is a simplified example of a P&ID used to represent the

batch mixing portion of the sample process shown on Drawing
#422-P&I Sheet 3 which is in Handout #2. Drawing #422-P&I
Sheet 3 uses Saudi Aramco symbology to identify the process,
and the loop components with functions and numbers. All
control signals in Figure 2 are electrical.

Saudi Aramco DeskTop Standards 12

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

The process shown in Figure 2 is designed to load fixed

amounts of products A and B into Batch Mixing Tank T-12.
When all the products are loaded into the batch mixing tank, the
combination is mixed for a fixed time period. At the end of the
mixing time, the mixing is stopped and the mixed product is
transferred to a storage tank. The transfer controls are not
shown on this portion of the P&ID. Components are included
which allow the operator to wash the mixing tank when all of the
product has been transferred to the storage tank.

YIC YIC
10 WASH 11
WATER
s s

FV10 FV11
YIC YIC
1 FQ MC FQ 2
1 12 2
s s
FE1 FE2
PRODUCT A FV1 FV2 PRODUCT B

LSH LAH
12 12A
L1 BATCH
12 MIXING TANK
T-12

AI LT LSL LAH
12 12 12B
12

S YIC
FV3
3

TO TRANSFER
PUMP

Figure 2. Batch Mixing System

Saudi Aramco DeskTop Standards 13

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

The P&ID is one of the prime documents required for a PLC

system. From the P&ID, the system designer will determine the
amount and types of signals required as inputs and outputs for
the PLC system. The information is used to determine the size
of the PLC required for control of the system. Drawing #422-
P&I, Sheet 3, shown in Handout #2, represents the P&ID for the
simulator PLC system used in the course.

Binary Logic
Diagram
A Binary Logic Diagram is an engineering diagram that
represents the functional operation of a given device or system.
The logic diagram is not meant to convey the specific type of
hardware used to execute a function; instead it is meant to
define the functions that must be performed in order to obtain
the desired result. Therefore, while the actual hardware used
for the control system may be electromechanical or solid state
components, the logic sequence of operation is identical.

Saudi Aramco standard SAES-J-005, Instrument Drawings and

Forms, provides a standard set of symbols for the
documentation of sequences and interlocks. The standard
defines a complete set of symbols for the representation of
binary logic and time-related functions. Figure 3 shows an
example of a binary logic diagram.

PB - 1
STOP

AND
MANUAL START
AND TRANSFER
RUN
PERMISSIVE REQUEST

SH. 2

PB-1
START

AND

LAH-14
OR

SW-3
MANUAL

Figure 3. Binary Logic Diagram

Saudi Aramco DeskTop Standards 14

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Logic deals with rules that relate premise and conclusion

statements. These statements, in two-level logic, are either
TRUE or FALSE; that is, if the premise condition is FALSE, the
conclusion is FALSE. Logic statements that relate the premise
statement and the output conclusions may be expressed in an
algebraic form, a Boolean logic equation, or diagrammatically.
Logic diagrams represent logic functions drawn in diagrammatic
form.

The logic diagram uses AND, OR, and NOT functions

connected together to define a specific system operation.
Figure 3 depicts the logic for the manual start request for a
transfer pump. This diagram, like the P&ID, provides the basis
for the PLC application program developed by the PLC
programmer. A well-defined logic diagram is an excellent set of
directions for the programmer, and it helps to ensure that the
resulting system will function as required. Drawing PCI 113.01-
2, shown in Addendum C, represents the Binary Logic Diagram
for the simulator PLC system used in this course.

Cause and Effect

Chart
The Cause And Effect Chart shows the relationship between a
device in the control system and the time or event operation of
an output device. These diagrams are used to document
shutdown safety logic, control interlocks, and sequential control
functions.

The Cause And Effect Chart shown in Figure 4 indicates the

relationship between separator level switches and the valves
located on the separators. The 9 steps of the sequence defined
the valve positions for shutdown and high and low levels for the
3 separators.

PLC software incorporates a version of the cause and effect

diagram to define the relationship between PLC output signals
and control steps that are time-driven or event-driven.

Saudi Aramco DeskTop Standards 15

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

S-4 SEPARATOR X-1011

X-1011
X-1011
X-1011
SHEET

S-2 SEPARATOR X-1011

S-2 SEPARATOR X-1011
FLOW
ACTIVATING DEVICE

S-6 SEPARATOR
S-4 SEPARATOR

S-6 SEPARATOR
SERVICE
X - CLOSE, OFF

OUTPUT
O - OPEN, ON

HV4001
HV4002
HV4003
HV4004
HV4005
HV4006
INITIATING DEVICE
FLOW DESCRIP- 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2
SHEET SERVICE TION 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4
AREA 1 SHUTDOWN 1 X X X X X X
UNIT 12 SHUTDOWN 2 X X X X X X
3
X-1011 S-2 SEPARATOR LSH4001 4 X O
X-1011 S-2 SEPARATOR LSL4001 5 O X
X-1011 S-4 SEPARATOR LSH4002 6 X X O
X-1011 S-4 SEPARATOR LSL4002 7 O X
X-1011 S-6 SEPARATOR LSH4003 8 X X O
X-1011 S-6 SEPARATOR LSL4003 9 O X
10
11
12
13
14
15
16
17
18
19
20

Figure 4. Example Cause and Effect Chart for Documentation

Of Shutdown Requirements

Saudi Aramco DeskTop Standards 16

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

FUNCTIONS OF BASIC PLC COMPONENTS

Overall PLC Operation

As a control device, the PLC performs several functions. The

PLC monitors input signals generated by sensory input field
devices. Based on the input signals, the PLC makes logic
decisions. As a result of the logic decisions, the PLC takes
control action by sending signals to the actuators of the output
field devices. Figure 5 shows the basic relationship between
the PLC and the process.

The input field devices provide status information to the PLC.

The information is either the open or closed state of the field
device or its voltage or current magnitude. The PLC reads the
status information and stores a corresponding logic status value
in the memory section of the central processing unit (CPU).

Based on the logic status value stored in the memory, the PLC
solves the user control program. The user control program is
designed by the proponent to regulate the process. The user
control program determines the relationship between the status
information and the action to be taken by the PLC to control the
process.

After solving the user control program, the PLC takes control
action by turning the actuators of the output field devices to
either ON or OFF state. The PLC regulates the output field
devices that control a process based on status information
provided by the input field devices.

Saudi Aramco DeskTop Standards 17

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

PLC

PROCESSOR

MEMORY

POWER
SUPPLY
INPUT CENTRAL OUTPUT
INTERFACE PROCESSING UNIT INTERFACE

PROCESS
STATUS CONTROL
INFORMATOIN

Figure 5. PLC Operational Relationships

The PLC system consists of the PLC, the input devices, the
output devices, and peripheral equipment. The PLC consists of
the following components, which are discussed below:

• Input interface

• Output interface

• Central Processing Unit

- Processor

- Memory

- Power supply

• Programming terminal

• Programming software

Saudi Aramco DeskTop Standards 18

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

The Programmable Logic Controller is a microprocessor

industrial control device. The PLC is also known as a
Programmable Controller (PC) in many applications. Figure 6
shows the relationship of the structure of a PLC system. These
relation-ships are common for all PLC systems regardless of the
manufacturer.

INPUTS FROM
PILOT DEVICES: PLC SYSTEM
PUSHBUTTONS DIGITAL
AND LIMIT, OUTPUTS
PROXIMITY, SMALL LOADS
TEMPERATURE, PLC
PRESSURE AND
LEVEL SWITCHES

PROCESSOR

INTERFACE
INTERFACE

OUTPUT
POWER LOADS
MEMORY
INPUT

AND
ANALOG CONTACTORS
POWER SUPPLY
PROCESS
INPUT SIGNALS:
TEMPERATURE,
PRESSURE,
FLOW AND
LEVEL

ANALOG
OUTPUTS:
PROGRAMMING
TRANSDUCERS
PROGRAMMING METERS
SOFTWARE TERMINAL

Figure 6. PLC System Block Diagram

Saudi Aramco DeskTop Standards 19

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Input Interface

Input signals provide the status of the devices connected to the

PLC. The input interface converts high level field voltages into
a low level logic dc voltage, it filters the input signal, and it
provides electrical isolation between the high voltage side of the
input module and the signal used by the central processing unit.
The input interface structure includes an input module and
housing to physically hold the module.

Input signals may be digital, analog, maintained, or momentary.

Typical digital input signals come from pushbuttons, limit
switches, pressure, temperature, level, and flow switches,
and/or electromechanical relay contacts. Typical analog signals
come from process transmitters, thermocouples (t/c),
Resistance Temperature Detectors (RTD), and strain gauges.
All input signals are converted to digital data, and they are
transmitted through the Input/Output bus to the central
processing unit.

The signal level for the digital input signals ranges from 115V ac
to 5V dc. The signal level for the analog input signals ranges
from 4 to 20 mA dc for the process transmitters to resistance
change provided by the RTD. The PLC system designer
selects the proper input interface module that is required for the
input signal generated by the field device that is connected to
the PLC.

Output Interface

The output interface converts the low level logic signal from the
CPU into a high level voltage that is used by the output device.
The output interface electrically isolates the logic level signal
from the high voltage level output signal, and provides electrical
transient protection between the output field device and the
CPU.

Digital output signals are used to control motor starters,

solenoid valves, and pilot lights. Signal voltages vary from
115V ac to 5V dc. Analog output signals are used to modulate
valves open or closed, to control electric heaters, and to drive
indicating meters and recorders. Analog output signals range
from 4 to 20 mA dc or -10 to +10V dc.

Saudi Aramco DeskTop Standards 20

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Central Processing Unit

The central processing unit (CPU) consists of three parts:

processor, memory, and power supply.

Processor
The processor is a part of the central processing unit. The
function of the processor is to command and govern the
activities of the PLC. The processor performs this function by
interpreting and executing a collection of system programs
called the executive. The executive is a collection of
supervisory programs that are permanently stored in the PLC
memory and that are considered part of the CPU. In addition to
the task of controlling the PLC, the executive programs also
perform the communication between the PLC and the
programming terminal. Each PLC vendor has developed a
unique executive for its PLC. Therefore, PLCs that have been
obtained from different vendors have different executive
programming.

Memory
The memory is also a part of the central processing unit. The
memory stores data relating to the status of the input and output
devices connected to the PLC and the status of the user control
program. The user control program, which is also called the
application program, contains the logic for the control of the
process.

The processor and the memory shown in Figure 6 are separate

components. They may be mounted within the same main
processor enclosure or on different circuit card assemblies
mounted within the same enclosure. The enclosure is called a
rack.

Saudi Aramco DeskTop Standards 21

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Power Supply
The power supply converts power line voltage to a filtered,
regulated dc voltage for the operation of the processor,
memory, and logic circuits located in the input and output
interfaces (modules). In most cases, the power supply is
capable of supplying power to the processor, memory, and to a
limited number of input and output modules mounted in the
same rack as the processor and memory. If the number of input
and output modules in a system exceeds the capacity of the
power supply, additional power supplies are required.

The power supply used with the Allen-Bradley PLC is a

separate module normally mounted in the same rack as the
processor. The power supply may be mounted externally to the
rack containing the processor, and connected to the rack with a
power cable. The location and type of the power supply is a
function of the manufacturer, the system configuration, and the
power supply load requirements.

Programming Terminal

The programming terminal is the interface between the PLC and

the programmer during program development, documentation,
startup, and troubleshooting. The instructions to be performed
in the control program are coded and inserted into the PLC
memory at the programming terminal.

Programming terminals vary in size and capability from small,

hand-held units that are the size of a portable calculator to units
that are the size of personal computers, including laptop
computers. The personal computer provides the hardware base
for the various DOS-based software programs that are written
by PLC vendors and third party software vendors for editing and
programming the PLC.

The programming terminal is usually connected to the PLC only

while the program is being entered. Once the programming has
been completed, the device is disconnected.

Saudi Aramco DeskTop Standards 22

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

Programming Software

The programming software consists of programs that, when

loaded into the programming terminal, respond to specific
software instructions to enter commands into the PLC and to
make it perform specific tasks. Programming software may be
supplied by the PLC vendor or by software suppliers other than
the PLC vendor. Typically, programming software is designed
to operate under DOS or Microsoft Windows.

A specific programming software package is required for each

different PLC. In many cases, a different package for each
different PLC family is supplied by a given vendor. For
example, Allen-Bradley manufactures a series of different PLCs
labeled the PLC-2, PLC-3, and PLC-5. Because each PLC has
a unique programming language, a different programming
software package is required for each PLC.

Saudi Aramco DeskTop Standards 23

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

SUMMARY

The Programmable Logic Controller is an electronic control

device that can be programmed to control industrial process
operation. The PLC has evolved from the hard-wired and solid
state control systems used in industry for position control. The
PLC is used for sequence control. PLC system projects must
have accurate documentation. The documentation, called
scoping documents, include P&IDs, Binary Logic Diagrams,
Cause and Effect Diagrams, and descriptions of operational
requirements.

The PLC consists of seven basic components: input interface,

output interface, processor, memory, power supply,
programming terminal, and programming software.

Saudi Aramco DeskTop Standards 24

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

GLOSSARY

analog An expression of values that can vary continuously

between specified values.

analog signal A continuous signal that depends directly on voltage

or current magnitude to represent some condition.

Central Processing The part of the PLC that governs system activities,
Unit including the interpretation and execution of
programmed instructions. Also known as the
CPU.

chassis A hardware assembly that contains PLC devices

such as CPU modules, I/O adapter modules, and
power supply. As a PLC unit, it becomes a rack
whenever modules are installed.

control logic The control plan for a given system. The program.

control system A system where deliberate guidance or

manipulation is used to achieve a prescribed value
of a variable. (See System.)

CPU See Central Processing Unit.

digital The representation of numerical quantities by

means of discrete numbers.

digital signal A signal that is discrete or discontinuous. A signal

that is ON or OFF. Sometimes called a discrete
signal.

documentation An orderly collection of recorded hardware and

software data such as tables, listings, and
diagrams. Documentation provides reference
information for PLC application, operation, and
maintenance.

Saudi Aramco DeskTop Standards 25

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

input A signal that provides information to the controller.

Input can be either discrete input (pushbutton, relay
contacts, limit switches) or numeric input
(thumbhole, external, solid state device).

input module A device that is used to connect the PLC with the
input devices. The input module contains the
circuitry required to convert the incoming voltages
to signal levels that are compatible with the
processor.

interface The boundary between two devices. A method of

integrating two elements of a system.

language A set of symbols and rules for representing and

communicating information (data) among people or
between people and machines.

logic A means of solving complex problems through the

repeated use of simple functions that define basic
concepts. Three basic logic functions are AND,
OR, and NOT.

logic diagram A drawing that represents the logic function or the

functional operation of a circuit. The operation is
defined by using AND or OR combinational logic to
represent system operation.

logic level The voltage magnitude associated with signal

pulses that represent ones and zeros in digital
systems.

memory The part of the PLC where data and instructions are
stored either temporarily or semi-permanently.

module An interchangeable, plug-in item containing

electronic components.

output A signal provided from the controller to a connected

device. Output signal can be in the form of control
data or as pure data for storage.

Saudi Aramco DeskTop Standards 26

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

output module A device that is used to connect the PLC with the
user's device. The output module contains the
circuitry required to convert the CPU's logic level
signals to voltage levels compatible with the user's
device.

PLC See Programmable Logic Controller.

power supply The unit that supplies the required voltage and
current to the system circuitry.

processor The part of the PLC that performs logic solving,

scans all inputs and outputs in a predetermined
order, monitors input and output status.

A solid state control device that can be

programmable to control a process operation.
Controller Also known as a PLC or a Programmable
Controller (PC).

rack See chassis.

read To acquire data from a storage device. Also, the

transfer of data between devices such as a
peripheral device and a computer. Also, to make a
copy of the data from a section of the PLC memory.

relay An electromagnetic device operated electrically.

When operated, it closes or opens contacts to
control other electrical circuits.

relay ladder logic A PLC programming language that is similar in style

to electromechanical ladder diagrams.

Scoping See Documentation.

documentation

software The user program that controls the operation of a

programmable controller.

Saudi Aramco DeskTop Standards 27

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

solid state Circuitry designed using only integrated circuits,

transistors, diodes, etc.; no electromechanical
devices such as relays are used.

status The present state of a device. For a digital device,

OPEN or CLOSED. For an analog device, the
value at a particular time.

system A group of interacting mechanical or electrical

components. Also, a set of one or more PLCs, I/O
devices and modules, computer peripherals,
terminals, and communication networks that
together provide information processing for
controlling machines or a process.

Saudi Aramco DeskTop Standards 28

Engineering Encyclopedia Introduction to Programmable Logic Controllers
Programmable Logic Controller (PLC):
PLC System Overview and Functions of Basic PLC Components

ADDENDUM: 34-SAMSS-830, SECTION 10: DOCUMENTATION

SECTION 10: DOCUMENTATION

10 DOCUMENTATION

10.1 Required Vendor’s Documentation

If the vendor is responsible for development of the application program, then he

shall provide the documentation listed in items A, B C, D and E. The vendor
shall always provide the documentation listed in items F, G, H, and I. Items A, B,
C, and D shall be generated by the program development workstation software
tools, and shall be transmitted to the buyer in hard (printout) and soft (diskette)
format.

a) Annotate printout of all programs or program files in ladder logic format

including all embedded address tag names, address descriptors, rung
comments, and network comments.
b) An index of the system data base including tag name(s) descriptors, and
initial values.
c) I/O and internal memory element allocations and cross reference.
d) A complete narrative describing the operation and sequence of each
network.
e) A complete marked-up (red-lined) set of buyer supplied binary logic
diagrams.
f) Cabinet/Rack interconnecting wiring diagrams, I/O module layout showing
all equipment with each I/O point labeled showing its associated
‘instrument tag number’ or labeled as a ‘spare’ point, cabinet fabrication
drawings;
g) Manufacturers standard Programming, Installation, Maintenance/
Troubleshooting Manuals, and Processor, Power Supply,
Communications, and I/O module specification sheets;
h) Factory Acceptance Tests (FAT) document detailing the set-up and
procedures for the Functional Test;
i) Recommended spare parts list and pricing, for two years of operation.

Saudi Aramco DeskTop Standards 29