CHAPTER 1 Process control system

Introduction
1.1 Conventional control panel
1.2 Control panel with a PLC controller
1.3 Systematic approach to designing a process control system

Introduction

A process control system is made up of a group of electronic devices that provide stability, accuracy and
eliminate harmful transition statuses in production processes. Operating systems can have different
arrangements and implementation, from energy supply units to machines. As technology quickly progresses,
many complex operational tasks have been solved by connecting programmable logic controllers and a central
computer. Beside connections with devices (e.g., operating panels, motors, sensors, switches, valves, etc.)
possibilities for communication among instruments are so great that they allow a high level of exploitation and
process coordination. In addition, there is greater flexibility in realizing a process control system. Each
component of a process control system plays an important role, regardless of its size. For example, without a
sensor, the PLC wouldn't know what is going on during a process. In an automated system, a PLC controller is
usually the central part of a process control system. With the execution of a program stored in program
memory, PLC continuously monitors status of the system through signals from input devices. Based on the logic
implemented in the program, PLC determines which actions need to be executed with output instruments. To
run more complex processes it is possible to connect more PLC controllers to a central computer. A system
could look like the one pictured below:


1.1 Conventional control panel

At the outset of industrial revolution, especially during sixties and seventies, relays were used to operate
automated machines, and these were interconnected using wires inside the control panel. In some cases a
control panel covered an entire wall. To discover an error in the system much time was needed especially with
more complex process control systems. On top of everything, a lifetime of relay contacts was limited, so some
relays had to be replaced. If replacement was required, machine had to be stopped and production too. Also, it
could happen that there was not enough room for necessary changes. control panel was used only for one
particular process, and it wasnt easy to adapt to the requirements of a new system. As far as maintenance,
electricians had to be very skillful in finding errors. In short, conventional control panels proved to be very
inflexible. Typical example of conventional control panel is given in the following picture.


In this photo you can notice a large number of electrical wires, time relays, timers and other elements of
automation typical for that period. Pictured control panel is not one of the more complicated ones, so you can
imagine what complex ones looked like.

Most frequently mentioned disadvantages of a classic control panel are:

- Too much work required in connecting wires
- Difficulty with changes or replacements
- Difficulty in finding errors; requiring skillful work force
- When a problem occurs, hold-up time is indefinite, usually long.

1.2 Control panel with a PLC controller

With invention of programmable controllers, much has changed in how an process control system is designed.
Many advantages appeared. Typical example of control panel with a PLC controller is given in the following
picture.

Advantages of control panel that is based on a PLC controller can be presented in few basic points:

1. Compared to a conventional process control system, number of wires needed for connections is reduced by
80%
2. Consumption is greatly reduced because a PLC consumes less than a bunch of relays
3. Diagnostic functions of a PLC controller allow for fast and easy error detection.
4. Change in operating sequence or application of a PLC controller to a different operating process can easily be
accomplished by replacing a program through a console or using a PC software (not requiring changes in wiring,
unless addition of some input or output device is required).
5. Needs fewer spare parts
6. It is much cheaper compared to a conventional system, especially in cases where a large number of I/O
instruments are needed and when operational functions are complex.
7. Reliability of a PLC is greater than that of an electro-mechanical relay or a timer.

1.3 Systematic approach in designing an process control system

First, you need to select an instrument or a system that you wish to control. Automated system can be a
machine or a process and can also be called an process control system. Function of an process control system is
constantly watched by input devices (sensors) that give signals to a PLC controller. In response to this, PLC
controller sends a signal to external output devices (operative instruments) that actually control how system
functions in an assigned manner (for simplification it is recommended that you draw a block diagram of
operations flow).

Secondly, you need to specify all input and output instruments that will be connected to a PLC controller. Input
devices are various switches, sensors and such. Output devices can be solenoids, electromagnetic valves,
motors, relays, magnetic starters as well as instruments for sound and light signalization.
Following an identification of all input and output instruments, corresponding designations are assigned to input
and output lines of a PLC controller. Allotment of these designations is in fact an allocation of inputs and outputs
on a PLC controller which correspond to inputs and outputs of a system being designed.

Third, make a ladder diagram for a program by following the sequence of operations that was determined in the
first step.
Finally, program is entered into the PLC controller memory. When finished with programming, checkup is done
for any existing errors in a program code (using functions for diagnostics) and, if possible, an entire operation is
simulated. Before this system is started, you need to check once again whether all input and output instruments
are connected to correct inputs or outputs. By bringing supply in, system starts working.


Chng 1 H thng iu khin qu trnh

Gii thiu
1.1 bng iu khin thng thng
1.2 Bng iu khin vi mt b iu khin PLC
1.3 Cch tip cn h thng thit k mt h thng iu khin qu trnh

Gii thiu

Mt h thng iu khin qu trnh c to thnh t mt nhm cc thit b in t cung cp
n nh, chnh xc v loi b trng thi chuyn tip c hi trong qu trnh sn xut. H
iu hnh c th c s sp xp v thc hin khc nhau, t n v cung cp nng lng cho
my. Khi cng ngh mt cch nhanh chng tin trin, nhiu nhim v hot ng phc tp
c gii quyt bng cch kt ni cc b iu khin logic lp trnh v mt my tnh trung
tm. Bn cnh cc kt ni vi cc thit b (v d, bng iu hnh, ng c, cm bin, thit
b chuyn mch, van, vv) kh nng giao tip gia cc thit b l rt ln h cho php mt
mc cao v khai thc v phi hp x l. Ngoi ra, c s linh hot hn trong vic thc
hin mt h thng iu khin qu trnh. Mi thnh phn ca mt h thng iu khin qu
trnh ng mt vai tr quan trng, bt k kch thc ca n. V d, khng c mt b cm
bin, PLC s khng bit nhng g ang xy ra trong mt qu trnh. Trong mt h thng t
ng, mt b iu khin PLC thng l trung tm ca mt h thng iu khin qu
trnh. Vi vic thc hin mt chng trnh c lu tr trong b nh chng trnh, PLC lin
tc theo di tnh trng ca h thng thng qua cc tn hiu t cc thit b u vo. Da trn
logic thc hin trong chng trnh, PLC xc nh cc hnh ng cn phi c thc hin vi
cc cng c u ra. Chy cc quy trnh phc tp hn c th kt ni nhiu b iu khin PLC
vi mt my tnh trung tm. Mt h thng c th trng ging nh mt hnh di y:


1.1 bng iu khin thng thng

giai on u ca cuc cch mng cng nghip, c bit l trong nhng nm su mi v
by mi, chuyn tip c s dng vn hnh my mc t ng, v chng c kt ni
vi nhau bng dy bn trong bng iu khin. Trong mt s trng hp mt bng iu
khin c ton b mt bc tng. Khm ph mt li trong h thng nhiu thi gian l cn
thit c bit l vi h thng iu khin qu trnh phc tp hn. Trn u trang ca tt c
mi th, mt i ch lin lc tip cn hn ch, v vy mt s chuyn tip phi c thay
th. Nu thay th c yu cu, my phi c dng li v sn xut qu. Ngoi ra, n c
th xy ra m khng c ch cho nhng thay i cn thit. bng iu khin ch c s
dng cho mt qu trnh c th, v n khng phi l d dng thch ng vi cc yu cu
ca mt h thng mi. Theo nh bo tr, th in phi rt kho lo trong vic tm kim
li. Trong ngn hn, bng iu khin thng thng t ra rt linh hot. V d in hnh ca
bng iu khin thng thng c a ra trong hnh di y.

Trong bc nh ny, bn c th nhn thy mt s lng ln cc dy in, r le thi gian, gi
v cc yu t khc ca t ng ha in hnh cho thi k . Bng iu khin nh khng
phi l mt trong nhng hn nhng ngi "phc tp", v vy bn c th tng tng nhng
phc tp nh th no.

Nhc im thng xuyn nhc n nhiu nht ca mt bng iu khin c in l:

- Qu nhiu cng vic cn thit trong kt ni dy
- Kh khn vi nhng thay i hoc thay th
- Kh khn trong vic tm kim li, i hi lc lng lao ng lnh ngh
- Khi mt vn xy ra, thi gian gi ln l khng xc nh, thng l di.

1.2 Bng iu khin vi mt b iu khin PLC

Vi pht minh ra iu khin lp trnh, c nhiu thay i trong cch thc mt h thng iu
khin c thit k.Nhiu li th xut hin. V d in hnh ca bng iu khin vi mt b
iu khin PLC c a ra trong hnh di y.

u im ca bng iu khin l da trn mt b iu khin PLC c th c trnh by
trong vi im c bn:

1. So vi mt h thng iu khin thng thng, s lng dy cn thit cho cc kt ni
c gim 80%
2. Tiu th s gim ng k v mt PLC tiu th t hn mt lot cc chuyn tip
3. Chn on chc nng ca mt b iu khin PLC cho php pht hin li nhanh chng v
d dng.
4. Thay i trong trnh t hnh hoc p dng mt b iu khin PLC mt qu trnh iu
hnh khc nhau c th d dng c thc hin bng cch thay th mt chng trnh thng
qua mt giao din iu khin hoc s dng mt phn mm my tnh (khng i hi phi c
nhng thay i trong h thng dy in, tr khi b sung mt s u vo hoc thit b u
ra l cn thit ).
5. Nhu cu t ph tng thay th
6. l r hn nhiu so vi mt h thng thng thng, c bit l trong trng hp mt
s lng ln I / O c cn thit v khi chc nng hot ng rt phc tp.
7. tin cy ca mt PLC l ln hn so vi mt rle c in hoc mt b m thi gian.

1.3 Cch tip cn c h thng trong vic thit k mt h
thng iu khin qu trnh

Trc tin, bn cn phi la chn mt cng c hoc mt h thng m bn mun kim
sot. H thng t ng c th l mt my tnh hoc mt qu trnh v cng c th c gi
l mt h thng iu khin qu trnh. Chc nng ca mt h thng iu khin qu trnh lin
tc theo di bi cc thit b u vo (cm bin) m cung cp cho cc tn hiu iu khin
PLC. Trong phn ng ny, b iu khin PLC gi tn hiu n thit b u ra bn ngoi (c
tc) m thc s kim sot chc nng h thng nh th no mt cch giao (n gin ha n
c khuyn khch l bn v mt s khi ca dng hot ng).

Th hai, bn cn phi xc nh tt c cc cng c u vo v u ra s c kt ni vi mt
b iu khin PLC.Thit b u vo thit b chuyn mch khc nhau, cm bin v nh
vy. Thit b u ra c th l solenoid, van in t, ng c, r le, bt u t cng nh cc
cng c cho m thanh v nh sng Signalization.
Sau mt nhn dng ca tt c cc u vo v cc cng c u ra, ch nh tng ng c
gn cho u vo v ng ra ca mt b iu khin PLC. Giao ca nhng ch nh trong
thc t, vic phn b u vo v u ra trn mt b iu khin PLC tng ng vi u vo
v u ra ca mt h thng c thit k.

Th ba, thc hin mt s bc thang cho mt chng trnh bng cch lm theo trnh t
ca cc hot ng c xc nh trong bc u tin.
Cui cng, chng trnh c a vo trong b nh iu khin PLC. Khi kt thc vi lp
trnh, kim tra c thc hin i vi bt k li hin c trong mt chng trnh m (s dng
chc nng chn on) v, nu c th, ton b hot ng c m phng. Trc khi h
thng ny c bt u, bn cn phi kim tra li mt ln na cho d tt c cc cng c
u vo v u ra c kt ni vi u vo hay u ra chnh xc. Bng cch a hng cung
cp, h thng bt u lm vic.