60. Programmable Logic Systems (PLC)

Background

Programmable Logic Controllers are launched way back in 1970s and today PLC are being used in all the industries. The PLCs are being extensively used in manufacturing/ production, packing, raw material processing etc. for monitoring, regulatory and sequential control, safety interlocks, motion control, alarms and sequence of events recording, and various other tasks. These are operated either in standalone mode and or they are interfaced with SCADA/ DCS for enhanced functionality. The applications of PLCs are ever increasing with emphasis on automation for the improvement of productivity, quality and safety.

Course Description

This is an introductory course, which aims to build a good understanding about the basics of PLCs and it focuses on providing the practical aspects of PLC operations, programming, and engineering. The course covers PLC block diagram, architectures, operation, usage, instructions, applications, specifications and hardware selection, configuration and programming, documentation related to URS and FDS, wiring diagrams, installation and commissioning, troubleshooting and maintenance with focus.

A special emphasis on real life implementations, case studies and international standards would ensure participants to correlate the theory with their day to day practice. A brief introduction to hierarchical structure of control systems and PLC communications would help the participants to enhance their exposure related to control pyramid and interface to office automation systems.

Course Duration

five (05) days – Eight Hours per day – Total of 40 hrs

Course Objectives

Upon Completion of this course the participant will be able to

• Understand PLC fundamentals and programming languages
• Work with PLC programming using ladder logic
• Develop skills on PLC instructions
• Have knowledge on PLC Project Engineering, Design and Selection
• Understand PLC communications
• Become expert on PLC installation and commissioning
• Master the art of PLC maintenance and troubleshooting
• Have a brief exposure to hierarchical structure of control system

Who Should Attend?

Instrumentation, Electrical, Mechanical and Process Engineers, Project Engineers, Maintenance engineers and supervisors interested to work in the field of PLCs. The course will definitely be beneficial for the all the other department people concerned with the plant operations, maintenance and safety. It could be also useful for the procurement and quality personnel.

Training Methodology

Training will be delivered by the use of lectures, demonstration and lab exercises with emphasis on practical examples and case studies. Participants will be well accommodated and prepared throughout the program to work confidently in the field of PLC based automation.

Course Outline

Module (1)

• Background and Evolution of Process Control/ Automation
• Basic Concepts – Open /Close loop
• Continuous and Discrete Control
• Current Scenario – PLC and DCS based automation
• Hierarchical Structure of Control Systems
• PLC Block Diagram, Components, Architectures and Scan Cycle
• PLC programming Languages as per IEC 61131
• PLC hardware configuration and addressing
• PLC basic instructions – NO, NC, Set, Reset

Module (2)
• PLC instructions – Timers and counters
• PLC instructions – Arithmetic, Comparison
• PLC instructions – Move, Logic
• Hands on Lab Practice

Module (3)
• PLC instructions – Program Control
• PLC instructions – Analog Control
• PLC Advanced Instructions
• Hands on Lab Practice

Module (4)
• PLC Engineering
• Design/ Specifications and Selection
• Documentation and Project Engineering
• Panel and Field Wiring
• Installation and Commissioning
• Hands on Lab Practice

Module (5)
• PLC troubleshooting
• System Bits
• Fault Tables
• Data Watch Lists
• Introduction to HMI and SCADA
• PLC Communications RS232, RS485

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