taklimat plc july 2008

Welcome to Politeknik Tuanku Sultanah Bahiyah.

For PLC And CX-ProgrammerTraining Course.

Duration : 2 Days courseTime : 8.30a.m - 4.30p.m Instructor : Koh Foo Hin

En. Mohd Elias

Development of The Course

Day 1

8.30a.m -9.00a.m : Your understanding about PLC

9.00a.m -10.00a.m : Introduction of PLC

10.00a.m -11. 00a.m : System Configuration &

Features & Function &

Unit Specification & Components

11.00p.m - 12.00p.m : Basic Command with Basic Programming method.

2.30p.m - 4.30p.m : Exercise With Actual Application

Development of The Course

Day 2

8.30a.m -9.00a.m : Overview of PLC

9.00a.m -12.00a.m : Continue with new Exercise

2.30p.m - 4.30p.m : Exercise With Actual Application and briefing about the intermediate for PLC

What kind of control system in a plant

Start & StopOperation

What kind of control system in a plant

Contactors, relays, timers & countersin the control panel

ControllingControlling

Motor pump

Valve

Mixer

Read & DisplayRead & Display

Flow Rate

Float Level

Oxygen Level

Hardwire logic control circuit

Relay 1

StartStart StopStop

Relay 1

PumpTimer

TimerRelay 1 Solenoid

A picture of hardwire relay logic

What is PLC ?

ProgrammableProgrammableLogicLogicControllerController

A solid-state device used to control machine or process operation by means of a stored program and feedback from input and output devices

Introduction to PLCIntroduction to PLC

BrainBrainSense Action

You

See

Listen

Taste

Touch

Smell

Hand

Leg

Mouth

HumaHumann

CPU

MemoryInput

Output

ProgrammingDevice

Power Supply

SignalsfromSwitches,Sensors,etc

Signals tosolenoids,motor,lamps,etc.

Operate by monitoring input signals and providing output signals. When changes are detected in the input signals, the PLC reacts, through the user-programmed

internal logic, to produce output signalsIt continuously scans the program in its memory to

achieve this control

PLC

PLCPLC HardwireHardwireLogicLogic

Control Device

Specific Purpose

General Purpose

Wired LogicWired Logic PLCPLC

Control sequence isControl sequence isfixed for one designfixed for one design

Control sequence can beControl sequence can bechange from time to timechange from time to time

without need to rewirewithout need to rewire

Wired LogicWired LogicPLCPLC

Control Scale

Small & Medium Medium & Large

Modification

An example for hard wire logic

Relay 1

StartStart StopStop

Relay 1

Pump

Timer

Timer

Relay 1Solenoid

Relay 1

StartStart StopStop

Relay 1

Pump

Counter

SolenoidRelay 1

Counter

#30StopStop

Hardwire logic will need to rewire everything

Modification

The same example for PLC

Relay 1

StartStart StopStop

Relay 1

Pump

Timer

Timer

Relay 1Solenoid

LD STARTOR RELAY 1AND NOT STOPOUT RELAY1OUT SOLENOIDLD RELAY 1TIM 000

#0020LD TIM 000OUT PUMP

Modification

The same example for PLC

Only need to change the ladder program

Relay 1

StartStart StopStop

Relay 1

Pump

Counter

SolenoidRelay 1

Counter

#30StopStop

LD STARTOR RELAY 1AND NOT STOPOUT RELAY1OUT SOLENOIDLD RELAY 1LD STOPCNT 000

#0030LD CNT 000OUT PUMP

Wired LogicWired Logic PLCPLC

Delivery Period

Several days Almost Immediate

MaintenanceDifficult Easy

LED indicator

Wired LogicWired LogicPLCPLC

Input/output connectorcan be remove easily

without using screw driver

ProgrammingConsole

Economic Efficiency

Advantage onsmall scale

Advantage onsmall, medium

and large

$$$$$$Wired LogicWired Logic PLCPLC

Power Consumption

High Low

0.2 Amp> 2 Amp

WiredWired LogicLogic PLCPLC

What PLC can doWhat PLC can do

Sequence ControlSequence ControlSequence ControlSequence Control

Relay 1

StartStart StopStop

Relay 1

Pump

Timer

Timer

Relay 1Solenoid

Relays

Timers & Counters

Sophisticated ControlSophisticated ControlSophisticated ControlSophisticated Control

+-x/

2

1

3 4

5

Prod Pass RejectAA 33 4BB 27 3CC 43 8

Arithmetic Operation

Analog ControlInformation Handling

Supervisory ControlSupervisory Control

PLC

Computer

PrinterFA

Network

Process Monitoring

Pager

Why & When to use PLCWhy & When to use PLC

Dramatically increase in population and housing developmentLimited landLimited land for plant

Upgrading of small plant to run higher capacity would involve complicated controlcomplicated control system, Intermittently Decanted Extented Aeration (IDEA).

A higher capacityhigher capacity of plant with high efficiency required

For that purpose, PLCPLC can do the job

Nation-wide Coverage

ElcompTradingElcompTrading

AutovationAutovation

RobomaticsRobomatics

OmmuraOmmura

EM SystemEM System

OMRON ELECTRONICS SDN.BHD

SALES NETWORK IN MALAYSIA

Waste Water Treatment Article

Reliable Control Solution For Waste Water TreatmentAnd Environmental Processes

In 1990, Omron controls were selected for a central FloridaWater treatment plant to ease capacity, productivity,efficiencyand reliability. The facility performed :

• Raw Water Pumping• Softening• Filtering • Storage / Distribution

The system included a PLC based station at each major processing stages, tied together with a triple-redundant network.The PLC / Computer network improved efficiency at the Water Treatment facility for about one-third the cost of a distributed control system.

One PLC control and monitors the softener systems ; two more PLCs control the filter systems; another PLC, located in the control room, controls the main storageand distribution system

Two independent host computer link networks connect the PLCs to the Computers. A peer to peer network provides a shared memory area to all PLCs on the network so that critical data - valve position, tanklevels, motor status and various plant flows are communicated automatically. This communicationis transparent to the users

Operator interface terminalssimplify control and monitoring of the entire operation. Fiber optic cables were installed for all communications networks to protect againstlightning

Data acquisition was automated by gathering all parameters from the PLCs data memories and printing

daily and monthly reports. Chemical and turbidity test results

were input into the computer byoperators for report generation

Future Expansion & Upgrading

DA

AD

Humidity Sensors

OC

OC

IDIDID

Inverter

Pumps House: 2

Pressure Interlock,

Power monitor

RS232 C

ModemDistance : 5km ~

8km

Maintenanceoffice(SCADA) Modem

RS232CPumps House: 1

Inverter

Pump 2 Pump 1 Jockey Pump

C1 C2

DA

AD

OC

OC

IDIDID

C1 C2

Pump 2 Pump 1 Jockey Pump