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Programmable Logic Controllers (PLC) & SCADA System
Course Overview
SCADA has traditionally meant a window into the process of a plant and/or a method of gathering of data from devices in the field. Today, the focus is on integrating this process data into the actual business and using it in real-time. In addition to this, today’s emphasis is on using Open Standards, such as communication protocols (eg IEC 60870, DNP3, and TCP/IP) and ‘off-the-shelf’ hardware and software, as well as focusing on keeping the costs down. PLCs continue to gain in popularity. In fact, many SCADA applications use PLCs as the RTU of choice, when communicating with field devices. This comprehensive course covers the essentials of SCADA and PLC systems, which are often used in close association with each other.
This course is designed to benefit you with practical up-to-date information on the application of PLC systems to the automation and process control industries. It is suitable for people who have little or no exposure to PLCs but expect to become involved in some or all aspects of PLC installation. It aims to give practical advice from experts in the field, to assist you in correct planning, programming, and installing a PLC with a shorter learning curve and more confidence. While the workshop is ideal for electricians, technicians, and engineers who are new to PLCs, much of the material covered will be of value to those who already have some basic skills, but need a wider perspective for larger and more challenging tasks ahead.
The accompanying manual includes contributions from a number of experts and will become a valuable reference document in your work. The information covered advances from the basics to challenge even the most experienced engineer in the industry today.
Course Objectives:
On successful completion of this workshop delegates will be able to:
- Fundamentals of SCADA systems
- Essentials of SCADA software configuration
- Tricks and tips for installation of SCADA systems
- Essentials of telecommunications links
- Use of Industrial Ethernet in SCADA systems
- OPC and SCADA systems
- SCADA network security issues
- How to troubleshoot SCADA systems
- Specifying PLC hardware and installation criteria
- Describe PLC software structure
Who Should Attend?
This course is designed for those who will be programming, installing equipment, maintaining equipment, purchasing or implementing cost reduction and automation programs, or maintaining and troubleshooting PLC-based equipment. Manufacturing Engineers, Industrial Engineers, Plant Operations Managers, Maintenance Personnel or other personnel involved in the planning, design, and setup of manufacturing facilities and personnel who encounter control systems in their course of daily functions should also attend.
Course Contents:
Module (01) Introduction
1.1 Introduction and a brief history of PLCs
1.2 Alternative control systems – where do PLCs fit in?
1.3 Why PLCs have become so widely accepted
1.4 Lingering concerns about PLCs
Module (02) Fundamentals of PLC Hardware
2.1 Block diagram of typical PLC
2.2 PLC processor module – memory organization
2.3 Input and output section – module types
2.4 Power supplies
Module (03) Background to SCADA
3.1 Fundamentals and definition of terms
3.2 Comparison of SCADA, DCS, PLC, and Smart instruments
3.3 Typical SCADA installations
Module (04) SCADA System Hardware
4.1 Comparison of SCADA, DCS, PLC, and Smart instruments
4.2 Remote Terminal Unit (RTU) structure
4.3 Analog and digital input/output modules
4.4 Application programs
4.5 PLCs used as RTUs
4.6 Master site structure
4.7 Communications architectures
4.8 Point-to-point and point-to-multipoint systems
4.9 System reliability and availability
4.10 Configuration of a master station
Module (05) Fundamentals of PLC Software
5.1 Methods of representing Logic, Boolean
5.2 Algebra, instruction code, and graphical presentation
5.3 Fundamental ladder logic instruction set
5.4 Comparison of different manufacturers, memory and data representation, and instruction code
Module (06) Using Ladder Logic for Simple Digital Functions
6.1 The basic rules
6.2 Comparison of relay ladder diagrams
6.3 The concept of the ‘scan’ and how to apply it
6.4 Infinite fan-out
6.5 Contact ‘normal’ states
6.6 Positive and negative logic
6.7 Basic Boolean functions
6.8 The usefulness of DeMorgan’s Law
Module (07) SCADA Systems Software
7.1 Components of a SCADA system
7.2 Software – design of SCADA packages
7.3 Configuration of SCADA systems
7.4 Building the user interface
7.5 Connecting to PLCs and other hardware
7.6 SCADA system design
7.7 The Twelve Golden Rules
Module (08) Advanced Control with PLC
8.1 The concept of reusable logic
8.2 Examples, drive logic and alarm handling
8.3 Use of advanced programming functions
8.4 Matrix logic
8.5 Table functions and indirect addressing
8.6 Example: simple display driver
Module (09) Batch Processes and Sequential Control
9.1 Remembering the program state
9.2 Creating a ‘stepper’
9.3 Step advance
9.4 Fault detection and recovery
9.5 Operator intervention
9.6 Multiple recipes or alternative paths