Plc and scada basics and application
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The document provides an overview of programmable logic controllers (PLCs), including their functions, hardware, programming, and role in industrial processes. PLCs are designed to operate under severe conditions and handle inputs from sensors and outputs to actuators in real-time. They are widely used for process control and safety systems due to their reliability, robustness, and long lifespan.
Plc and scada basics and application
- 1. FE Technologies PLC basis… EN-ICE-PLC Jerónimo ORTOLA Benjamin BRADU plc.support@cern.ch
- 2. PLC Programmable Logic Controller Designed for industrial processes. Works under severe conditions. Real time system. Handles sensors and actuators (I/O). PLC- Overview
- 3. Process control Collects inputs (digital, analog) Runs the process control Basic logic functions Complex algorithms (PID…) Safety functions Produces actions (outputs) Provides data to the supervision layer PLC- Functions
- 4. Reliable. Used for safety systems. Robust. Resistant to electrical noise, vibration, impact, dust, heat. Extensive range of inputs/outputs. Extensive range of functionalities. Long term support by suppliers. Long life, around 30 years. PLC- Strength
- 5. Limited memory. Special programming environment. Different programming languages from different manufacturers. PLC- Weak points
- 6. PLC- Hardware Overview ETHERNET TCP/IP INDUSTRIAL FIELDBUS REMOTE I/O PLC SENSORS/ACTUATORS DIRECT WIRING Supervisory Control And Data Acquisition SCADA
- 7. Device which converts the signal from one form to another. Sensors Analog: Temperature, pressure, humidity, level, flow, weight… Digital: Level, pushbutton (emergency stop), position switch, photoelectric sensor… Actuators Analog: valve, pump, heater, power supply… Digital: Signaling column, contactor, electro valve, switch, OnOff pump… PLC- Sensors / actuators
- 8. PLC- Hardware Overview ETHERNET TCP/IP INDUSTRIAL FIELDBUS REMOTE I/O PLC SENSORS/ACTUATORS DIRECT WIRING Supervisory Control And Data Acquisition SCADA
- 9. Communication modules. I/O Modules. Convert physical value into numeric value and vice versa. Function modules. PLC- Periphery stations
- 10. Ethernet Profibus CAN Point to Point Serial RS 232, RS 485 AS-Interface Modbus… PLC- Communication modules
- 11. Analog 16-bit signed from -32768 to 32767. Inputs: Resistance, Current, Voltage, thermocouple… Outputs: Current, voltage. Digital 1-bit Inputs: 120v-230v AC, 24v DC Outputs: Relay, 120v-230v AC, 24v-48v-125v DC. PLC- Input / Output modules
- 12. PID control Flow Camera controllers Numerical controllers Counters Positioning Motor VFD or Soft Starter PLC- Function modules
- 13. PLC- Hardware Overview ETHERNET TCP/IP INDUSTRIAL FIELDBUS REMOTE I/O PLC SENSORS/ACTUATORS DIRECT WIRING Supervisory Control And Data Acquisition SCADA
- 14. Industrial Network System Provides the PLC with I/Os Time deterministic. PLC- FieldBus. Overview
- 15. Controls multiple I/Os Saves cabling costs Safety compliant PLC- FieldBus. Strength
- 16. Sensitive to electromagnetic noise Specific installation rules. Several different (incompatible) fieldbus standards. PLC- FieldBus. Weak points
- 17. Profibus (Siemens) Industry leader. 14 million nodes. WorldFip Robust (radiation resistant) CAN. CANOpen. CANBus Low cost, Easy to implement Used for ELMB at CERN ProfinetIO (Siemens) Ethernet based EtherNet/IP (Schneider) Ethernet Based PLC- FieldBus. Standards
- 18. PLC- Profibus. Technical data Standard PROFIBUS EN 50 170 Access Token ring . Master-Slave Transmission rate 9.6 kbit/s - 12 Mbit/s Transmission technology electric: Shielded cooper pair twisted cable optic: fiberoptics (cristal and plastic) wireless: infrared and radio Nodes 127 maximun Network lenght electric: 9.6 km maximun optic: 150 km maximun Topology Daisy Chain, tree, star, ring, redundant ring Used for Process communication, data transfer
- 19. PLC- Profibus PROFIBUS Active nodes. Master Passive nodes. Slaves. PLC PLC PC
- 20. PLC- Hardware Overview ETHERNET TCP/IP INDUSTRIAL FIELDBUS REMOTE I/O PLC SENSORS/ACTUATORS DIRECT WIRING Supervisory Control And Data Acquisition SCADA
- 21. PLC- Supported at CERN Siemens CERN-SIEMENS B1130A/GEN 31-12-1999 Schneider CERN-SCHNEIDER. B1129/GEN 12-11-1999
- 22. PLC- Siemens S7 200 (low range) Compact Low cost Small systems
- 23. PLC- Siemens S7 300 (medium range) Modular Wide range of IOs Widely used Limited memory Limited range of fieldbuses
- 24. PLC- Siemens S7 400 (high range) Redundant architecture Large memory High performance
- 25. Small range (M340) 4 Mb of memory 1024 digital I/O 256 analog I/O PLC- Schneider Medium range (PREMIUM) 7 Mb of memory 2040 Digital I/O max 512 Analog I/O High range (QUANTUM) 8 Mb of memory 8 000 Digital I/O 2500 Analog I/O
- 26. WriteOutputs Read Inputs OS communication tasks USER APPLICATION (time consuming) Cycle time 5-500 msec Process Cycle PLC- Processor
- 27. PLC- Memory access, IO access Internal 16 bits IO devices are mapped in Data area a memory. %MW120 0 N word Real %MF137 %IW0.2.3 %QW0.2.3 Input word Output word %I0.6.3.1 %Q0.7.3.6 Input Boolean Output Boolean Access to The Module Channel in The Module Bit in the Channel %Q0.7.3.6 := TRUE; %QW0.2.3 := 16#0F00; %MW100 := 12; 120 137 138
- 28. Languages defined in IEC 61131-3 Textual languages Instruction List (IL) Structure Text (ST) Graphical Languages Ladder (LD) Functional Bloc Diagram (FBD) Sequence (Stepper) Sequential Function Chart (SFC) 28 PLC- Programming languages
- 29. PLC- Programming languages - IL IL: Instruction List Fastest possible logic execution. Low level language Similar to assembly language
- 30. PLC- Programming languages - ST ST: Structured Text High level language Equations, table manipulation Complex algorithms (If/Then)
- 31. PLC- Programming languages - LD Traditional ladder logic is an easy-to-use graphical programming language that implements relay-equivalent symbol. Intuitive. Limited functionalities.
- 32. PLC- Programming languages - FDB FBD : Function Block Diagram Easy way of programming Easy way of debugging Limited for complex algorithms
- 33. PLC- Programming languages - SFC SFC : Sequential Function Chart – A graphical method of representing a sequential control system (stepper).
- 34. Siemens : Simatic Step7 v5.5 Modular Wide range of functionalities Diagnostic tools Network configuration Schneider : UNITY Pro v7.0 Easy to manage Visualization facilities PLC- Programming software tools
- 35. PLC- Hardware Overview ETHERNET TCP/IP INDUSTRIAL FIELDBUS REMOTE I/O PLC SENSORS/ACTUATORS DIRECT WIRING Supervisory Control And Data Acquisition SCADA
- 36. Ethernet TCP IP. Big amount of data transfer. Non deterministic. Big data transfer rates. S7 Driver on TCP IP. Siemens. Modbus Driver on TCP IP. Schneider. OPC. PLC- SCADA communication
- 37. UNICOS – A CERN Approach UNICOS : UNified Industrial COntrol System Based on PVSS/PLC systems for Continuous Process Control (CPC) Cryogenics for LHC, ATLAS, CMS and other non-LHC cryo Experiments Detector Gas Systems (LHC experiments) Vacuum, Cooling & Ventilation Based on PVSS as SCADA with other Front-Ends (Industrial Computers) Interlock Systems (PIC, WIC, QPS) Power of the PS (POPS) Cryogenic instrumentation (CIET) Alignment of inner triplets (SURVEY) Based on a hierarchical object approach Can be applied in Front-End(Schneider & Siemens PLC or FEC with FESA) Can be applied in SCADA (PVSS) Easy to use CERN services and link different control systems UNICOS helps operation teams and developers (standardization)
- 38. Data point types + Widgets + Faceplates UNICOS – What he is doing for me? PLC C Object definition (Baseline) DFB (or FB) + DDT (or UDT) Data point creation Object instantiation FB (or DB) Data point configuration affect addresses to signals Memory mapping affect addresses to signals Generic Logic feedbacks, I/O links, Errors.. Logic structure sections (or FC) Complete Logic -Interlocks -Object Dependent Logic Communication configuration Communication configuration SCADA O Specifications Generators - Grafcet definitions - Transition Logic Synoptic building By drag & drop
- 39. UNICOS – PVSS screen layout
- 40. Front-End technologies 40 Summary- EN-ICE Services CERN-wide support Field buses, PLC DIP, OPC, CANbus What we provide Architecture and design recommendations List of recommended tools/cards Validation of new commercial software versions Maintenance of custom software “Hands On” facility for you to practice “Show Case” facility as a demonstrator
- 41. Front-End technologies 41 Thank You FE-Technologies- End plc.support@cern.ch
- 42. Front-End technologies 42 FE-Technologies- Summary Technologies seen EN-ICE Support What comes next..
- 43. Front-End technologies 43 FE Technologies- Technologies Supervision Experimental equipment LAN PLC VME Field Bus Process Sensors/devices Field buses & Nodes PLC OPC SCADA Unix systems DIM FSM Custom Client Server Profinet Modus Subscriber CERN API/Driver OPC DIM DIP Servers DIP Publisher DIP Publisher Server Manufacturers I. Protocols Other systems (LHC, Safety, ...) Scada Communications Commercial Custom DIM/DIP
- 44. Front-End technologies 44 Summary- EN-ICE Services First-line support for research sector Field buses, PLC, DIP, DIM CERN-wide support DIP, OPC, CANbus What we provide Architecture and design recommendations List of recommended tools/cards Validation of new commercial software versions Maintenance of custom software “Hands On” facility for you to practice “Show Case” facility as a demonstrator
- 45. Front-End technologies 45 Thank You FE-Technologies- End icecontrols.support@cern.ch http://cern.ch/en-ice
- 46. Front-End technologies 46 Location and Time Schedule Schedule Tuesday–Friday: 09:00-12:30 14:00-17:30 Monday: 14:00-17:30 Location Building: Training Center 593-572 Room #25