PLCFundamental

PLC Fundamental
Dr. Ir. Endra Joelianto
MANAGEMENT
⚫ Measure actual operational performance against

key performance indicators.
⚫ Provides a sophisticated data model that allows
data to be consolidated into a single database, yet
sensitive data may be restricted to only privileged
users.
⚫ Collected data may be used to document
environmental regulatory compliance.
⚫ Integration of plant data to business applications
automatically will provide informed business
decision
PT. Mairodi Mandiri Sejahtera

www.pelatihan-indonesia.id
1
OPERATION
⚫ Review on entire operational performance and

trends (rather than unit by unit) from a single
location since data from a variety of systems is
consolidated into a single database.
⚫ Long-term data storage enabling high volumes
data can be analyzed to ensure best practices,
while incidents can be analyzed and avoided.
⚫ Key performance indicators could be exposed to
operators, allowing them to understand how
ongoing decisions affect the bottom line.
OPERATION COMPONENTS
⚫ Operation (Control) Room

⚫ Operator
⚫ Human Machine Interface (HMI)
⚫ Programmable logic Controller (PLC)
⚫ Cable
⚫ Power Supply
⚫ Sensors/Actuators
⚫ Plants/Systems
➔ Can be seen physically

2
OPERATION COMPONENTS
⚫ Management Software
⚫ HMI Software
⚫ Interface Software
⚫ PLC Software
⚫ Sensors/Actuators Software
⚫ Plant/Systems Software
➔ Software ➔ PROGRAM ➔ Programming

➔ Programmer
PROGRAMMING
⚫ Translating the problems into a step-by-step

code
⚫ The process of writing, testing and
maintaining the code
➔The first step in every software development

project should be requirements analysis,
followed by modeling, implementation, and
failure elimination (debugging).

3
⚫ The process of writing source code requires
expertise in many different subjects:
– including knowledge of the application domain
– algorithms to implement the desired behavior
Programming (the implementation) is

regarded as one phase in a software
development process.
PROGRAMMER
⚫ A programmer or software developer is someone

who programs PLC, that is, one who writes PLC
software.
⚫ The term programmer can refer to a specialist in
one area of PLC programming or to a generalist
who writes code for many kinds of software.
⚫ Those proficient in programming skills may
become famous, though this regard is normally
limited to software engineering circles.
⚫ Algorithm is an expression of implementation on
PLC.

4
⚫ The first step in every software development
project should be:
– Analysis
– Modeling
– Implementation
– Failure elimination (debugging).
⚫ There exist a lot of differing approaches for
each of those tasks.
PROGRAMMING
⚫ Early PLCs, up to the mid-1980s, were programmed using
proprietary programming panels or special-purpose
programming terminals, which often had dedicated function
keys representing the various logical elements of PLC
programs.
⚫ Programs were stored on cassette tape cartridges. Facilities
for printing and documentation were very minimal due to lack
of memory capacity.
⚫ More recently, PLC programs are typically written in a special
application on a personal computer, then downloaded by a
direct-connection cable or over a network to the PLC.
⚫ The very oldest PLCs used non-volatile magnetic core
memory but now the program is stored in the PLC either in
battery-backed-up RAM or some other non-volatile flash
memory.

5
⚫ Early PLCs were designed to be used by
electricians who would learn PLC programming on
the job.
⚫ These PLCs were programmed in "ladder logic",
which strongly resembles a schematic diagram of
relay logic.
⚫ Modern PLCs can be programmed in a variety of
ways, from ladder logic to more traditional
programming languages such as BASIC and C.
⚫ Another method is State Logic, a Very High Level
Programming Language designed to program PLCs
based on State Transition Diagrams.
⚫ Recently, the International standard IEC 61131-3

has become popular. IEC 61131-3 currently defines
five programming languages for programmable
control systems:
– FBD (Function block diagram)
– LD (Ladder diagram)
– ST (Structured text, similar to the Pascal programming
language)
– IL (Instruction list, similar to assembly language)
– SFC (Sequential function chart). These techniques
emphasize logical organization of operations.

6
⚫ While the fundamental concepts of PLC
programming are common to all
manufacturers, differences in I/O
addressing, memory organization and
instruction sets mean that PLC programs
are never perfectly interchangeable
between different makers.
⚫ Even within the same product line of a
single manufacturer, different models may
not be directly compatible
$$/month •Plant Management •Production Planning •Quality Management

$$/quarter Data Exchange / Plant Integration
•Calculate Key Performance Indicator •Perform Data Reconciliation •Data Exchange with Other System
$$/day
Value Added Engineering
•Show Production Cost / Management Reports •Perform Mass Balancing Report •History Data Analysis
$$/month Applications
•Provide Data History •Show Long-Term Trends •Study Alarms & Events
•Easy Access to Live/History Data Data Historian
•Show Weekly/Monthly Reports •Study Process
& Availability
xx/day
xx/month Plant Information Management System Office
Control Room
•Show ‘live’ data Monitoring & Control
•Plant Operation •Display Mimics •Show 10 minute Trend •Print Daily Report
xx/min
xx/hour
Process Control System
Field
xx/s
xx/ms Field Sensors / Actuators

7
OPERATION PURPOSES
DATA PRODUCTION
ENERGY MONITORING PERFORMANCE ENVIRONMENTAL
RECONCILIATION ACCOUNTING
MONITORING MONITORING
PROCESS PLANT ECONOMIC CHARACTERISTICS MATERIALS

PLANT FEED ERP
UNIT
TANK
PLANT MODEL INTERMEDIATE
FINISHED PRODUCT
CMMS
EDMS
FACILITY CHEMICALS
STREAM TECHNICAL CHARACTERISTICS UTILITIES
Infor. Manag. Syst. OPERATIONS ACTIVITY

LocalIMS MANAGEMENT
DATA MANAGER
HISTORICAL REAL TIME REFERENCE

DATABASE DATABASE DATABASE
OPC CLIENT
OPC SERVER
Dr. Ir. Endra Joelianto PCs
ejoel@tf.itb.ac.id 15
USER INTERFACE
⚫ PLCs may need to interact with people for the

purpose of configuration, alarm reporting or
everyday control. A Human-Machine Interface
(HMI) is employed for this purpose.
⚫ A simple system may use buttons and lights to
interact with the user. Text displays are available as
well as graphical touch screens.
⚫ Most modern PLCs can communicate over a
network to some other system, such as a computer
running a SCADA (Supervisory Control And Data
Acquisition) system or web browser.

8
COMMUNICATIONS
⚫ PLCs usually have built in communications

ports for at least RS232, and optionally for
RS485, RJ45 (ethernet) and USB.
⚫ Modbus is the lowest common denominator
communications protocol. Others are
various fieldbuses such as Profibus,
DeviceNet, AS-Interface.
⚫ Other communications protocols that may
be used are listed in the List of automation
protocols.
CURRENT SYSTEMS
18

9
❖ Architecture of Distributed Control System
human machine interface
Operator
Operation and
interface to other systems monitoring function
Display and
engineering interface
Operator operation function
station
Human - machine
database
Other System Communication
system Engineer
Communication Gateway System configuration,
between other
System maintenance
systems
Control Control
data-base data-base
Control
station
Control Control
function function
DDC/SEQ DDC/SEQ
Process Process
process interface
❖ DCS Components
❑ Operator station
▪ Collects data relating to the process operation
▪ Displaying and manipulating the process data
❑ Control station
▪ Contains control function
❑ Communication system
▪ Exchanges data between the operator station, control
station and
other stations

10
❖DCS Interfaces
❑ Human – machine Interface

❑ Engineering Interface
❑ Interface to other systems
❑ Process Interface
❖ Human-Machine Interface
❑ Interface between the DCS and the operator

❑ Central monitoring of the plants
❑ Gives up-to-date plant information to the operator using
graphical user interface
❑ Translates operator instruction into the machine
❑ It permits the operator to perform
▪ operations
▪ maintenance and troubleshooting Operator Console
▪ development ▪ Microprocessor
▪ CRT
▪ Keyboard

11
❖ Engineering Interface
❑ Interface between the DCS and the engineers

❑ It permits system build-up and software maintenance in the DCS
❑ Engineering development station
❖ Interface to Other System
❑ Supervisory computer interface

▪ Connects the DCS to a supervisory computer
▪ Transmits control data and receives supervisory operation
commands and optimal setting
❑ Control sub-system interface
▪ Connects the DCS to other types of instruments
▪ Programmable Logic Control (PLC)
▪ Composition analyzer to integrate plant operation
▪ etc

12
❖ Process Interface
▪ Interface between the DCS and the plant (field instruments)

▪ The control station receive measurement signals from sensors and
perform control calculation in accordance with the deviations from
the set-point values
▪ Output signals are sent to the final control elements to performs
compensatory actions
❖ Goals
Improving plant control system
❑ Production
▪ Optimizing the production schedule
▪ Optimizing the equipment assignments
❑ Consistency product
❑ Efficiency
▪ Energy and material saving
❑ Safety
❑ Cost
▪ Plant-wide optimization
▪ Optimization of personnel utilization

13
❖ Why Distributed Our Control ?
Ease of implementation
❑ Hardware
▪ Many modules alike
▪ Cable connected versus hardwiring
❑ Software
▪ No programming but library of configuration modules “cut
and paste”
▪ Fewer mistakes
❑ Understanding
▪ Fewer hardware types to buy, learn and repair
▪ Fewer mistakes
Why Distributed Our Control ? (continued)
Operator Productivity
❑ Easy to see change
❑ More information to make good decisions
❑ Improved ability to respond to any upset
❑ Consistent actions by all operators
❑ Fewer upset

14
❑ Flexibility Plant Efficiency

▪ Hardware modules
▪ Software modules
❑ Sophisticated control
▪ Analog and discrete on same module
▪ Comprehensive interlocks easily implemented
❑ Extensive information
▪ Available to suggest improvements
❑ Optimization
▪ Local
▪ Plant wide
Maintenance of Records
❑ Process history
▪ Plant operations
▪ System change and growth
▪ Various configurations
❑ Suggest improvements
▪ Trend of process
▪ Analysis (X-Y, Xbar, etc)
▪ Relational database manager (RDBM)

15
Reliability
❑ Distributed risk
❑ Redundant paths
❑ Graceful degradation
❑ Fast detection of any system failure
❑ Easier to replace parts
❑ Longer life time
Improved Maintenance
❑ Improved visibility of many types of system problems
❑ Diagnostics for rapid discovery and location
❑ Performance statistics provide advanced warning
before catastrophic failures
Long Life Cycle

16
Easy Expansion & Change

❑ Capability and Capacity
❑ No reprogramming
▪ Existing system will accept new additions
❑ Modules all alike
▪ Add only what is needed
▪ Nothing to buy ahead of time
❑ No need to know the future
▪ Nature of changes
▪ Amount of changes
▪ Timing of changes…….or even if they will occur
❖ DCS System Configuration

❑ Configuration is generally done from a workstation
❑ All controllers are as one database that allows for peer-to-peer communication in
complex strategies
❑ The database may reside only in workstation, with copies in controllers, sometime
downloading is needed during the backup of redundant controllers
❑ Views, history, and trend will also have to be configured
❑ Separate PCs, usually add-on, must configure unique links to control and views,
etc, on separate database as with PLC "add-on"
PC
PC configured
as HMI separately
Some proprietary Network often based as HMI
Workstation upon a Physical Standard
Workstation
as HMI
as HMI
Controller Controller Controller Controller
Single database configured for all stations


17
❖ OLE for Process Control (OPC)
❑ Object Linking and Embedding (OLE) for Process Control

❑ A standard for process automation communications
❑ A standard software mechanism for sharing data between
process automation of different manufacturers
❑ OPC is based on Microsoft OLE (Object Linking and Embedding)
and DCOM (Distributed Component Object Model)
❑ OPC advantage :
▪ Simple to implement
▪ Flexible to accommodate multiple vendor needs
▪ Provide a high level of functionality
▪ Allow for efficient operation
❖ Dynamic Data Exchange (DDE)
❑ An application protocol that allows data exchange on real-time

basis on Windows/WindowsNT platforms
❑ NetDDE = Dynamic Data Exchange over network
I/O Devices
Driver
Tag Database
DDE Link
Windows DDE Windows DDE Other

Application Application Applications

18
Typical Applications - Network
☺Level 2 : Hosts
• Recipe data downloads
• Production data uploads
• Application programming and management
☺Level 1 : Control
• peer to peer coordination
• HMI displays
☺Level 0.5 : I/O

• Intelligent devices
☺Level 0 : Devices
• Pushbutton / simple sensors
PLC Range Schneider
TSX Quantum
Complexity,
Connectivity TSX Premium
TSX Micro
500 I/O upwards
TSX Twido
300 to 2000 I/O
50 to 300 I/O
10 to 264 I/O


19
PLC Range OMRON
Complexity,
Connectivity CS Series
CJ Series
CQM1H
CPM 2C-S 5120 I/O
CPM 2A
CPM 1A
2560 I/O
512 I/O
362 I/O
120 I/O
100 I/O
❖ Programmable Logic Controller (PLC)
for Distributed Computing

outputs
inputs
❑ Processor
I/O System Power Supply
❑ Memory
❑ I/O Interface
❑ Programming PROCESSOR
Device &
Languages
❑ Power Supply Programming Memory
Device Unit


20
❖ Typical PLC System Configuration
Human-Machine Interface Programming Device
PLC Network
PLC PLC PLC PLC
FIELD DEVICES
Typical PLC System Configuration (continued)

❑ Each PLC must be configured separately
❑ Discipline is needed to avoid duplicating process tags
❑ Complex strategies are generally confined to individual PLCs
❑ PC must be configured to communicate with each PLC to find specific variables
then configured for views, history, trends etc.
❑ PLC systems usually have multiple databases to configure and keep matched
Some proprietary Network that passes as de facto
PC Physical and Communication Standard
as HMI
PLC PLC PLC PLC
each individually configured
Must configure to communicate with each PLC, to link views, etc.

21
❖ Advantages of PLC
❑ Excellent logic handling capabilities; operating and

maintenance personel
❑ Easily understand ladder logic
❑ Very fast, with the ability to detect a malfunction within a few
milliseconds
❑ Very cost effective, allowing them to be customized to the
product functions
❑ Can withstand rough environment
❑ Highly reliable
❑ Offer high level of flexibility and expandability
❑ Very compact and do not have large space requirements
❖ The Main Drawbacks of PLC
❑ Nondeterministic
❑ Limited in its continuous loop control capabilities
❑ Need for host computer or PC to interface with process control and other
more complex operations
❑ Batch control software is typically not available for the process control
vendor in hybrid system using both DCS and PLCs
❑ Available user interfaces do not always have the capability of those provided
with distributed controls; use of HMIs from other vendors limits PLCs
capabilities
❑ The need to configure the PLCs is separate from configuring computers and
DCSs in those systems that combine these
❑ PLC vendor companies and their distributors generally lack process
experties, requiring the services and costs of an independent integrator

22
Comparison of Computer Control Type (generalization)
Typical strengths Typical weakness
▪ Distributed risk ▪ Entry level cost
▪ Real-time throughput ▪ Proprietary network
DCS ▪ Advanced control strategy ▪ Proprietary OS
▪ PID (3 mode control) ▪ Complex interlocks
▪ Operator interface ▪ Control room environment
▪ Low integration cost
▪ Environmental ▪ Human interface

PLC ▪ Uptime
▪ Real-time throughput
▪ Integration cost
▪ Sequencing
▪ Complex interlocks ▪ Reporting
▪ RLL easy and repeatable ▪ Application software
▪ Recipe handling
▪ Data acquisition ▪ Programmed
Central ▪ Advanced control strategy

▪ Database storage
▪ Environmental limits
▪ Costly redundancy
Computer ▪ History and trending

▪ Networking
▪ Real-time throughput
Comparisons by Execution (scan) Times (generalization)

Scan Time Typical Functions Likely System
1 Month ▪ Corporate update of plant Computer
▪ Operation summary
1 Day, shift ▪ Production report
1 Hour ▪ Off-line optimization
▪ Batch management DCS
▪ Batch scheduling
1 Minute ▪ Unit process optimization DCS
1 Second ▪ Display update
▪ Analog control
▪ Process calculations
▪ Batch sequencing
100 mSec ▪ Flow control
▪ High-speed sequencing
20 mSec PLC
▪ Interlocks
1 mSec ▪ Sequence of events


23
I/O Types and amounts (DCS vs PLC)
over 150 Large DCS Large DCS with Large DCS with
Medium PLCs Large PLCs
Loop of
Small DCS Small DCS with Small DCS with
Modulating 30 to 150
Medium PLCs Large PLCs
Control
under 30 Small PLC with PC Medium PLC with Large PLCs with
or PC and SLCs PC or SLCs Integrated Workstation
under 200 200 to 600 over 600
Channels of discrete I/O
Open system configuration

Workstation Choice of open network flexibility or proprietary network security
or PC
as HMI
User Choice;
Uploads control database for : Single distributed control strategy :
 Screen views  Single configuration
 Trends  Each controller stores its own
 History - configuration
 etc - documentation
- tag names and HMI calls
- peer-to-peer links for complex strategies
- "bridge software" to populate HMI database

24
Emerging (ideal) configuration
PC Fieldbus open network flexibility

as HMI
Multivariable
Sensor Analyzer Valves Motors
Controller
User Choice;
Configures control database
and
 Screen views Smart transmitters, sensors, end elements :
 Trends  Multivendor within same system
 History  Common function blocks
 etc - configuration
- documentation
- tag names and HMI calls
- peer-to-peer links for complex strategies
DIFFERENCIES
⚫ DCS as replacement for ⚫ PLC as replacement for

panel board instruments, wired electrical relays and
primarily for continuous mechanical timers, primarily
control, as in refineries in manufacturing of
individual parts
⚫ Language Function Blocks ⚫ Use Ladder Logic
intended for continuous Programming to perform
control high speed discrete control
in factory

25
CURRENT POSITION
⚫ DCS and PLC began independently of the other and each was
designed to fit different control problems
⚫ DCS and PLC are control systems that based on
microprocessor
➔Both DCS and PLC adapt each other features: A

HYBRID CONTROLLER (Honeywell / OMRON) that
has both power for continuous control and discrete
control
IEC 61131-3
No single language is best for all aspects of control

⚫ Continuous control : Function Block
⚫ Discrete Control : Ladder Logic
⚫ Sequencing : SFC
⚫ Programming : Structured Text
➔ IEC specification states that these languages must

interact in order to provide a comprehensive control
solution
➔ Intermix the languages on a single sheet

26
YOKOGAWA
IDEC

27
Siemens S7-200/300/400
S7-1200/1500

28
Mitsubishi Q/F


29
Allen-Bradley SLC500/PLC5/Controllogix/

30
Modicon M340/Quantum/Twido
PLC
PLC Twido Compact & Modular

31
Perbedaan antara PLC dan Smart Relai
⚫ PLC :
1. Dapat melakukan fungsi-fungsi aritmatik.
2. Dapat melakukan operasi-operasi pemindahan
memori.
3. Dapat melakukan fungsi-fungsi yang komplek
seperti : sequence, LIFO, FIFO, PWM, dll.
⚫ Smart Relai :
Hanya dapat melakukan fungsi-fungsi logika dan
beberapa fungsi dasar seperti timer dan counter.
Siemens : LOGO

32
Smart Relai → Schneider: Zelio
Omron : ZEN Mitsubishi : ALPHA

33
Allen-Bradly: PICO

34

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PLC Fundamental

Dr. Ir. Endra Joelianto

⚫ Measure actual operational performance against

PT. Mairodi Mandiri Sejahtera

⚫ Review on entire operational performance and

⚫ Operation (Control) Room

PT. Mairodi Mandiri Sejahtera

➔ Software ➔ PROGRAM ➔ Programming

⚫ Translating the problems into a step-by-step

➔The first step in every software development

PT. Mairodi Mandiri Sejahtera

Programming (the implementation) is

⚫ A programmer or software developer is someone

PT. Mairodi Mandiri Sejahtera

PT. Mairodi Mandiri Sejahtera

⚫ Recently, the International standard IEC 61131-3

PT. Mairodi Mandiri Sejahtera

$$/month •Plant Management •Production Planning •Quality Management

PT. Mairodi Mandiri Sejahtera

PROCESS PLANT ECONOMIC CHARACTERISTICS MATERIALS

Infor. Manag. Syst. OPERATIONS ACTIVITY

HISTORICAL REAL TIME REFERENCE

⚫ PLCs may need to interact with people for the

PT. Mairodi Mandiri Sejahtera

⚫ PLCs usually have built in communications

PT. Mairodi Mandiri Sejahtera

PT. Mairodi Mandiri Sejahtera

❑ Human – machine Interface

❑ Interface between the DCS and the operator

PT. Mairodi Mandiri Sejahtera

❑ Interface between the DCS and the engineers

❖ Interface to Other System

❑ Supervisory computer interface

PT. Mairodi Mandiri Sejahtera

▪ Interface between the DCS and the plant (field instruments)

PT. Mairodi Mandiri Sejahtera

Why Distributed Our Control ? (continued)

PT. Mairodi Mandiri Sejahtera

❑ Flexibility Plant Efficiency

Why Distributed Our Control ? (continued)

PT. Mairodi Mandiri Sejahtera

Why Distributed Our Control ? (continued)

Long Life Cycle

PT. Mairodi Mandiri Sejahtera

Easy Expansion & Change

❖ DCS System Configuration

Single database configured for all stations

Dr. Ir. Endra Joelianto

PT. Mairodi Mandiri Sejahtera

❑ Object Linking and Embedding (OLE) for Process Control

❖ Dynamic Data Exchange (DDE)

❑ An application protocol that allows data exchange on real-time

Windows DDE Windows DDE Other

PT. Mairodi Mandiri Sejahtera

☺Level 0.5 : I/O

PLC Range Schneider

Dr. Ir. Endra Joelianto

PT. Mairodi Mandiri Sejahtera

❖ Programmable Logic Controller (PLC)