Module 6: Industrial Electrical Systems Automation

Study of basic PLC, Role of PLC in automation, advantages of process automation,

PLC based control system design, Panel Metering and Introduction to SCADA system
for distribution automation.

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Programmable Logic Controller (PLC) is a microcomputer-based controller that

uses instructions stored in programmable memory to implement logic,
sequencing, timing, counting, and arithmetic functions through digital or analog
modules, for controlling machines and processes.

A Programmable Logic Controller (PLC) is an industrial computer control

system that continuously monitors the state of input devices and makes
decisions based upon a custom program to control the state of output devices.

In other words, PLC is industrial computer used to control different electro

mechanical processes for use in manufacturing, plants, or other automation
environments.

Actually, before the development of microprocessors (i.e before 1980’s),

industrial logic and sequence control used to be performed using control panels
containing electromechanical or solid-state relays, contactors and switches,
indicator lamps, mechanical or electronic timers and counters etc., all hardwired
by complex and elaborate wiring. In fact, for many applications such control
panels are used even today. However, the development of microprocessors
quickly led to the development of the PLCs.

PLCs are widely used in a variety of industries because they’re fast, easy to
operate and are considered easy to program. PLCs can be programmed in
several ways, from ladder logic, which is based on electromechanical relays, to
specially adapted programming languages of BASIC and C. Most PLCs today
use one of the following 5 programming languages: Ladder Diagram, Structured
Text, Function Block Diagram, Instruction List, or Sequential Function Charts.

PLC act as the physical interfaces between device on the plant or manufacturing
floor and a SCADA system. PLCs communicate, monitor and control automated
processes like assembly lines, machine functions, or robotic devices.

Significant advantages of PLC over conventional control panels are-

 Programming the PLC is easier than wiring physical components; the only
wiring required is that of connecting the I/O terminals.
  The PLC can be reprogrammed using user-friendly programming devices.
Controls must be physically rewired.
 PLCs take up much less space.
 Installation and maintenance of PLCs is easier, and in present day reliability
is grater compared with solid-state technology.
 The PLC can be connected to a distributed plant automation system,
supervised and monitored.
 Ability of PLCs to accept digital data in serial, parallel and network modes
imply a drastic reduction in plant sensor and actuator wirings, since single
cable runs to remote terminal I/O units can be made. Wiring only need to be
made locally from that point

Comparing Logic and Sequence Control with Analog Control

The salient points of difference between Analog Control and Logic/Sequence

control are presented in the table below:
Issue Logic/Sequence Control Analog Control
Model Logical Numerical
State-Transition Differential/ Difference Eqn.
Simple Model/ Easy to build Complex Model/ Hard to build
Infrequent Liable to change
Signal Signal range/status Signal value
Temporal
(Timed) sequence (Timed)Function/Trajectory
Property
Control On-off/logical linear/non linear analog
Redesign/ Supervisory automatic
Tuning Open/Closed Loop Open/Closed Loop
Infrequent Tuning needed

Application of PLC:

Programmable Logic Controllers are suitable for a variety of automation tasks.

They provide a simple and economic solution to many automation tasks such as

 Logic/Sequence control
 PID control and computing
 Coordination and communication
 Operator control and monitoring
 Plant start-up, shut-down

PLC is suitable for any manufacturing application that involves controlling

repetitive, discrete operations e.g. machine tool, automatic assembly equipment,
molding and extrusion machinery, textile machinery and automatic test
equipment. Some Industrial Areas for use of PLC are-
 Chemical/ Petrochemical Metals Manufacturing/Machining
Batch process Blast Furnace Material Conveyors, Cranes
Pipeline Control Continuous Casting Assembly
Weighing, Mixing Rolling Mills Milling, Grinding, Boring
Finished Product Handling Soaking Pit Plating, Welding, Painting
Water/ Waste Treatment Steel Melting Shop Molding/ casting/forming

Basic Component of PLC

A PLC’s functions are divided into three main categories: inputs, outputs and the CPU. PLCs
capture data from the plant floor by monitoring inputs that machines and devices are
connected to. The input data is then processed by the CPU, which applies logic to the data,
based on the input state. The CPU then executes the user-created program logic and outputs
data or commands to the machines and devices it is connected to.
Central Processing units
The CPUs are generally micro programmed processors sometimes capable of handling
multiple data width of either 8, 16 or 24 bits. In addition sometimes additional circuitry is
provided, since much of the computing involves logical operations involving digital inputs
and auxiliary quantities. Memory with battery backup is also provided for the following:

 Flags (internal relays), timers and counters;

 Operating system data
 Process image for the signal states of binary inputs and outputs.
The user program is stored in memory modules. During each program scan, the processor
reads the statement in the program memory, executes the corresponding operations. The bit
processor, if it exists, executes binary operations. Often multiple central controllers can be
configured in hot standby mode, such that if one processor fails the other can immediately
pick up the computing tasks without any failure in plant operations.

Program and Data memory

The program and data needed for execution are stored in RAM or EPROM sub modules.
These sub modules are plugged into the processors. Additional RAM memory modules can
also be connected.

Input / Output Modules

There are two main types of inputs: data inputs from devices and machines, and data inputs
that are human-facilitated. The input data from sensors and machines are sent to the
PLC. Inputs can include on/off states for things like mechanical switches, buttons, and
encoders. High/low states for things like temperatures, pressure sensors, and liquid-level
detectors, or opened/closed states for things like pumps and values. Human-facilitated inputs
include button pushes, switches, and sensors from devices like keyboards, touch screens,
remotes, or card readers.
Outputs are the physical actions or visual results that are based on PLC logic in response to
those inputs. Physical outputs include starting motors, turning on a light, draining a valve,
turning the heat up or a pump off. Visual outputs are sent to devices like printers, projectors,
GPSs, or monitors.
Input and output modules are connected to the PLC bus to exchange data with the processor
unit. These can be broadly categorized as follows:
Digital Input Modules: The digital inputs modules convert the external binary signals from
the process to the internal digital signal level of programmable controllers.
Digital Output Modules: The digital output modules convert the internal digital signal levels
of the programmable controllers into the binary signal levels required externally by the
process.
Analog Input Modules: The analog input modules convert the analog signals from the
process into digital values which are then processed by the programmable controller.
Analog Output Modules: The analog output modules convert digital values from the
programmable controller into the analog signals required by the process.
Special Purpose Modules: These may include special units for
 High speed counting
 High accuracy positioning
 On-line self-optimizing control
 Multi axis synchronization, interpolation
These modules contain additional processors, and are used to relieve the main CPU from the
high computational loads involved in the corresponding tasks.
Programming Devices
External programming units can be used to download programs into the program memory of
the CPU. The external field programmers provide several software features that facilitate
program entry in graphical form. The programmers also provide comprehensive aids for
debugging and execution monitoring support logic and sequence control systems. Printer can
be connected to the programmers for the purpose of documenting the program. In some cases,
special programming packages that run on Personal Computers, can also be used as
programming units.

There are two ways of entering the program:

A. Direct program entry to the program memory (RAM) plugged into the central controller.
For this purpose, the programmer is connected to the processor or to the programmer
interface modules.

B. Programming the EPROM sub modules in the programmer without connecting it to the PC
(off-line). The memory sub modules are then plugged into the central controller.

Other units such as Power Supply Units (mainly 24 V DC), Bus Units etc. can also be
connected to the PLC system.

PLCs operate in cycles. First, the PLC detects the state of all input devices that are connected
to it. The PLC applies the user-created logic, and then executes it based on the input
states. The PLC then outputs commands to any output device connected to the PLC either
turning them on or off. The PLC resumes the cycle each time the process is completed.
Need of programmable logic controller (PLC) in automation:
1. PLCs are similar to industrial computers. PLCs can work as standalone units that can
continuously monitor and automate a process. PLCs can be networked; such a network can
control an entire production line. PLCs can be adapted to monitor and control many sensors
and actuators; they process electrical signals and use them to carry out preprogrammed
commands for almost any application. PLCs are used in industrial automation to increase
reliability, system stability and performance, minimizing the need for human operators and
the chances of human error.

2. PLC is used in the fully automated industries or plants or process, the actual processes
handled and controlled by the controllers which are nothing but the programming logic
controllers that means PLC plays a very important role in automation section.

2. PLCs constantly monitor the state of the systems through input devices and generate the
control actions according to the logic given in the user program.

3. It is a heart of control systems, PLC monitors the state of the system through field input
devices, feedback signals and based on the feedback signal PLC determine the type of action
to be carried out at field output devices.

4. PLC provides easy and economic solution for many automation tasks like
 Operates control and monitoring
 Co-ordination and communication
 PID computing and control
 Logic / sequence control

Industrial Automation
Industrial Automation is a process of operating machines and other industrial equipment with
the help of digital logical programming and reducing human intervention in decision making
and manual command process with the help of mechanized equipment. The automation
process typically uses devices such as PLCs, PCs, PACs, etc. and various types of industrial
communication technologies.
Some of the examples of automated industrial processes are:
 Packaging and material handling
 Quality control and inspection
 Metal fabrication; machining, welding, cutting, cladding etc.
 Food and beverage processing
 Planning and decision making
Industrial Automation Advantages
 Reduction in production time – having a machine that is automated definitely speeds
up the production time since no thinking is needed by the machine; there is better
repeatability, and less human error.
 Increase in accuracy and repeatability – when an automated machine is programmed
to perform a task over and over again, the accuracy and repeatability compared to an
employee is far greater.
 Less human error – no one is perfect, and we are all prone to making mistakes. Which
is why a machine that performs repeated tasks is less likely to make mistakes than an
employee?
 Less employee costs – by adding automated machines to an operation, means less
employees are needed to get the job done. It also indicates less safety issues, which
leads to financial savings. With having less employees, there are numerous costs that
are diminished or reduced such as payroll, benefits, sick days, etcetera.
 Increased safety – having automated machines means having fewer employees who
perform tasks that can be dangerous and prone to injury, which can make the work
environment safer.
 Higher volume production – investing in automated equipment creates a valuable
resource for large production volumes, which in turn, will increase profitability.