Higher

Nationals
Unit 4033: Programmable Logic Controllers

Assignment Brief
Programme Title Pearson BTEC Level 4 Higher National Certificate in
Electronic Systems Engineering for England

Student Name/ID Number

Unit Number and Title 4033 Programmable Logic Controllers

Academic Year 2024-2025

Unit Tutor Sohail Shah

Assignment Title 1/2, Understanding Programmable Logic Controllers

17/12/2024
Issue Date

Submission Date 17/01/2025

Submission Format
The assignment submission is in the form of an MS Word document Technical Report. It is essential that any
texts, diagrams, pictures, information copied from books, journals, publications, Internet, etc., is referenced
properly using the Harvard Referencing System. The work should go through Turnitin before submission.

Unit Learning Outcomes

LO1 Describe the design, operation and selection of PLC systems

LO2 Explore Functional Safety within PLC systems

Transferable skills and competencies developed

Working with Programmable Logic Controllers (PLCs) develops a wide range of transferable skills and
competencies. It enhances technical skills in programming, electrical engineering, and automation control,
while also strengthening analytical and problem-solving abilities, such as troubleshooting and data analysis.
Proficiency in IT and digital communication technologies, is also developed. Understanding industrial systems,
maintaining safety standards, and optimizing processes are key competencies gained.
Vocational scenario
Bekaar Industries, a prominent manufacturing company specializing in plastic moulding components, is
committed to enhancing its production processes through continuous improvement initiatives. They are
currently exploring the integration of programmable logic controllers (PLCs) into their manufacturing
operations.

You have been appointed as a consultant to provide expertise in understanding and implementing PLC
systems within Bekaar’s manufacturing facilities. You are experienced in Siemens S7-1200 PLC hardware, and
therefore propose this PLC for any future projects.
As the lead consultant you will also be responsible for ensuring the functional safety of PLC systems utilized in
various processes such as assembly, machining, and quality control of product parts. Your role is therefore
pivotal in preventing accidents, safeguarding workers, and upholding high-quality production standards.

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Assignment Brief and Guidance
Task:
Before any project development, the client has requested a technical report to reassure themselves that
investing in a PLC system is the right thing to do. This technical report will consist of two parts:
Part 1:
The client would like you to address the following knowledge-based questions:
 What is meant by “Compact”, “Modular”, and “Rack-mounted” PLC systems? Compare the design of
these types of PLCs, highlighting, advantages, and their potential applications.
 What is the typical architecture of a PLC? How do the hardware and software operate together to
make it a viable industrial controller?
 What types of input and output devices are available on PLCs? and the techniques used for interfacing
them.
 Should the PLC be programmed using only International Electrotechnical Commission (IEC) PLC
standard (IEC 61131–3: 2013) approved languages? Is this advisable? If so, can you provide an
explanation of what the languages are, how they differ, and advantages and disadvantages?
 What are the difference between Programmable Logic Controllers (PLCs) and Programmable
Automation Controllers (PAC’s)? What technology would be most suitable for specific automation
tasks within Bekaar’s production environment. Include factors such as complexity, scalability, real-
time processing, and integration capabilities in your response.
 Will the Siemens S7-1200 PLC be able to meet project requirements for cost-effectiveness,
performance, scalability and compatibility with existing systems? If so, justify your selection with any
industrial application.
Part 2:
In the second part of the report, the client would like you to address safety when using PLC systems. The
client has presented you with a potential new project to develop an autonomous robot arm for assembling
products on a production line. The robot arm will be performing tasks such as welding, cutting, and
assembling parts with high speed and precision. Safety is a critical issue during both normal operation and
maintenance activities.

As their safety consultant you have advised that a full functional safety assessment be conducted involving
either Hazard and Operability (HAZOP), or Failure Modes and Effects Analysis (FMEA). You will present the
findings of your assessment to the client in the second part of your report and should include:

 The necessity of functional safety within the given project. You will explain the importance of
integrating safety measures into PLC programming and operations to mitigate risks and ensure the
safety of workers and equipment on the production floor.
 Hazard and Operability (HAZOP) OR Failure Modes and Effects Analysis (FMEA) for the project. This
will cover identification of the potential hazards, severity assessment, and proposed safety measures
to mitigate risks effectively.
 A concluding evaluation on effectiveness of integrating functional safety measures into PLC systems
to minimize hazards and risks within Bekaar’s manufacturing facility. Evaluation to include factors
such as reliability, redundancy, diagnostic capabilities, and compliance with safety standards (e.g., IEC
61508, ISO 13849). Provide recommendations for further enhancing functional safety in PLC systems.

Submission Guidelines and Additional Instructions:

Prepare a word-processed technical report that is appropriately structured and addresses all of the
client knowledge queries and safety concerns. Remember that you are representing your employer, so

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it should have a professional appearance and be suitably referenced (e.g. Harvard, IEEE).

Seek clarification from your instructor if you encounter any difficulties or uncertainties regarding the
assignment requirements.

Avoid plagiarism by citing the sources used in your assignment appropriately.

Recommended Resources
Bolton W. (2015) Programmable Logic Controllers. 6th Ed. Elsevier.
Dawkins N. (ed.) (2014) Automation and Controls: A guide to Automation, Controls, PLCs and PLC
Programming.
Johnson Jr C.H. and Sanusi A.L. (2022) PLC Programming from Novice to Professional: Learn PLC
Programming with Training Videos (Paperback). Ojula Technology Innovations.
Manesis S. and Nikolakopoulos G. (2018) Introduction to Industrial Automation. 1st Ed. Routledge,
Taylor and Francis Group.
Perez A. E. (2012) Introduction to PLCs: A beginner’s guide to Programmable Logic Controllers.
Petruzella F. (2023) Programmable Logic Controllers. 6th Ed. McGraw Hill.
Stewart G.R. (2021) Siemens Plc Programming For Beginners: [Step-by-Step Instructions] How Can I
Quickly and Easily Learn PLC Programming at Home? Independent publication.
White M.T. (2023) Mastering PLC Programming: The software engineering survival guide to
automation programming (Paperback). Packt Publishing Limited.

Journals
Note: Example journals listed below provide a broad range of articles related to unit content and those
relevant for the qualification. Direct links available from unit specification.

 Automation and Remote Control

 Automation
 Electrical, Electronics and Communications Engineering (Applied Sciences)
 IFAC Journal of Systems and Control
 IEEE Journal on Robotics and Automation
 IEEE Potentials (Programmable Logic Controllers)
 International Journal of Automation and Control (IJAAC)
 International Journal of Innovative Research in Technology & Science
 Journal of AI, Robotics and Workplace Automation
 Journal of Automation and Intelligence
 Programmable Logic Controllers (Special issue)

Please note that the resources listed are examples for you to use as a starting
point in your research – the list is not definitive.

BTEC HN Assignment Brief Template

Issue Date: Jan 2024 Owner: HN QD
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Higher
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BTEC HN Assignment Brief Template

Issue Date: Jan 2024 Owner: HN QD
DCL1 Public (Unclassified) Version 2.0
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Learning Outcomes and Assessment Criteria

Pass Merit Distinction

LO1 Describe the design, operation and selection

of PLC systems

P1 Describe the M1 Analyse the D1 Justify the selection of a

architecture and operation suitability of programmable logic
of programmable logic programmable logic controller for a given
controllers. controllers (PLCs) application.
with programmable
automation
P2 Compare the design
controllers (PACs) for
and applications of
given applications.
Compact, modular and
rack-mounted PLCs.

P3 Describe the range of

input/output devices and
PLC interface techniques.

LO2 Explore Functional Safety within PLC D2 Evaluate functional

systems safety and its integration
into PLC systems to
P4 Explore the M2 Apply functional minimise hazards and risks.
requirement of functional safety analysis on a
safety within industrial PLC based
PLC systems. automated process
system.
P5 Compare the range of
IEC6113-3 languages and
their applications.

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STUDENT ASSESSMENT SUBMISSION AND
DECLARATION
When submitting evidence for assessment, each student must sign a declaration
confirming that the work is their own.
Student name: Assessor name:
Sohail Shah

Issue date: Submission date: Submitted on:

Programme: Pearson BTEC Level 4 Higher National Certificate in Electronic Systems

Engineering for England

Unit: 4033 – Programmable Logic Controllers

Assignment number and title: 1/2, Understanding Programmable Logic Controllers

Plagiarism
Plagiarism is a particular form of cheating. Plagiarism must be avoided at all costs and
students who break the rules, however innocently, may be penalised. It is your
responsibility to ensure that you understand correct referencing practices. As a
university level student, you are expected to use appropriate references throughout and
keep carefully detailed notes of all your sources of materials for material you have used
in your work, including any material downloaded from the Internet. Please consult the
relevant unit lecturer or your course tutor if you need any further advice.

Student Declaration

Student declaration
I certify that the assignment submission is entirely my own work and I fully understand the
consequences of plagiarism. I declare that the work submitted for assessment has been
carried out without assistance other than that which is acceptable according to the rules of the
specification. I certify I have clearly referenced any sources and any artificial intelligence (AI)
tools used in the work. I understand that making a false declaration is a form of malpractice.

Student signature: Date:

Higher Nationals - Summative Assignment Feedback

Form
BTEC HN Assignment Brief Template
Issue Date: Jan 2024 Owner: HN QD
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Student Name/ID

Unit Title Programmable Logic Controllers

Assignment Number 1/2 Assessor Sohail Shah

Date Received
Submission Date
1st submission
Date Received 2nd
Re-submission Date
submission
Assessor Feedback:

Grade: P / M / Assessor Signature: Date:

D /R
Resubmission Feedback:

Grade: Assessor Signature: Date:

Internal Verifier’s Comments:

Signature & Date:

Higher Nationals - Summative Assignment Feedback

Form

BTEC HN Assignment Brief Template

Issue Date: Jan 2024 Owner: HN QD
DCL1 Public (Unclassified) Version 2.0
 Higher
Nationals
Student Name/ID
Unit Title Programmable Logic Controllers

Assignment 1/2 Assessor Sohail Shah

Number
Date Received
Submission Date
1st
submission
Date Received 2nd
Re-submission
submission
Date
Assessor Feedback:
*Please note that constructive and useful feedback should allow students to understand:

a) Strengths of performance
b) Limitations of performance
c) Any improvements needed in future assessments
Feedback should be against the learning outcomes and assessment criteria to help students understand
how these inform the process of judging the overall grade.

Feedback should give full guidance to the students on how they have met the learning outcomes
and assessment criteria.

I certify that to the best of my knowledge the evidence submitted for this assignment is the student’s own. The
student has clearly referenced any sources and any artificial intelligence (AI) tools used in the work. I have not
solely used AI to grade the student’s work.

Grade: Assessor Signature: Date:

Resubmission Feedback:
*Please note resubmission feedback is focused only on the resubmitted work

Grade: Assessor Signature: Date:

Internal Verifier’s Comments:

Signature & Date:

* Please note that grade decisions are provisional. They are only confirmed once
internal and external moderation has taken place and grades decisions have
been agreed at the assessment board.

BTEC HN Assignment Brief Template

Issue Date: Jan 2024 Owner: HN QD
DCL1 Public (Unclassified) Version 2.0