Professional Certificate of Competency in Programmable Logic Controllers (PLCs) & SCADA Systems

Overview

This comprehensive course covers the essentials of SCADA and PLC systems, which are often used in close association with each other. A selection of case studies are used to illustrate the key concepts with examples of real world working SCADA and PLC systems in the water, electrical and processing industries.

This course will be an excellent opportunity to network with your peers, as well as to gain significant new information and techniques for your next SCADA / PLC project. Although the emphasis of the course will be on practical industry topics highlighting recent developments, using case studies, the latest application of SCADA, PLC technologies and fundamentals will be covered.

The inevitable question is which PLC is being used. We present this course focusing on the generic PLC and use the open programming IEC 61131-3 standard. For specific examples we use the Allen Bradley range, but are not selling Allen Bradley or for that matter any other PLC!

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 to correctly plan, program and install a PLC with a shorter learning curve and more confidence. While the course 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 information covered advances from the basics to challenge even the most experienced engineer in the industry today.

Course Outline

MODULE 1: INTRODUCTION

• Introduction and brief history of PLCs
• Alternative control systems - where do PLCs fit in?
• Why PLCs have become so widely accepted
• Lingering concerns about PLCs

FUNDAMENTALS OF PLC HARDWARE

• Block diagram of typical PLC
• PLC processor module - memory organisation
• Input and output section - module types
• Power supplies

MODULE 2: BACKGROUND TO SCADA

• Fundamentals and definition of terms
• Comparison of SCADA, DCS, PLC and
• Smart instruments
• Typical SCADA installations

SCADA SYSTEM HARDWARE

• Comparison of SCADA, DCS, PLC and Smart instruments
• Remote Terminal Unit (RTU) structure
• Analog and digital input/output modules
• Application programs
• PLCs used as RTUs
• Master site structure
• Communications architectures
• Point-to-point and point-to-multipoint systems
• System reliability and availability
• Configuration of a master station

MODULE 3: FUNDAMENTALS OF PLC SOFTWARE

• Methods of representing Logic, Boolean Algebra, instruction code and graphical presentation
• Fundamental ladder logic instruction set
• Comparison of different manufacturers, memory and data representation and instruction code

USING LADDER LOGIC FOR SIMPLE DIGITAL FUNCTIONS

• The basic rules
• Comparison of relay ladder diagrams
• The concept of the 'scan' and how to apply it
• Infinite fan-out
• Contact 'normal' states
• Positive and negative logic
• Basic Boolean functions
• The usefulness of DeMorgan's Law

USING REGISTERS (WORDS)

Number systems, Timers, Types of register data, Counters, Bit shift and rotate, Table functions and Register (Matrix) logic functions

MODULE 4: SCADA SYSTEMS SOFTWARE

• Components of a SCADA system
• Software - design of SCADA packages
• Configuration of SCADA systems
• Building the user interface
• Connecting to PLCs and other hardware
• SCADA system design
• The Twelve Golden Rules

MODULE 5: GOOD PROGRAMMING HABITS

• Keeping track of addresses and data used
• Looking ahead - how will programs be maintained?
• Practical methods to improve quality: organisation of code, thorough documentation and simplifying changes

GOOD INSTALLATION PRACTICE

• Location of hardware
• Good wiring practice
• Cable spacing, power distribution and wire numbering
• Reducing noise and interference
• Screening and shielding

MODULE 6: HUMAN MACHINE INTERFACES (HMIs)

• Human and ergonomic factors
• HMI configuration
• Design and layout
• Alarming and reporting philosophies
• Alarm system design

GOOD INSTALLATION PRACTICE

• Recommended installation practice
• Ergonomic considerations

MODULE 7: ADVANCED CONTROL WITH PLCs

• The concept of reusable logic
• Examples, drive logic and alarm handling
• Use of advanced programming functions
• Matrix logic
• Table functions and indirect addressing
• Example: simple display driver

BATCH PROCESSES AND SEQUENTIAL CONTROL

• Remembering the program state
• Creating a 'stepper'
• Step advance
• Fault detection and recovery
• Operator intervention
• Multiple recipes or alternative paths
• Sequential function charts

PID CONTROL

The importance of timing and scan time

When PID is not always appropriate:

• Intermittent measurements
• Long transport delays

SAFETY PROGRAMMABLE SYSTEMS

• Why regular PLCs should not be used for safety functions
• Programmable electronic logic solvers
• Safety certification
• Certified programming systems
• Application examples
• Growth of networked safety devices and certified networks
• Integrated safety systems

MODULE 8: LANDLINE MEDIA

• Background to cables
• Noise and interference on cables
• Twisted pair cables and fibre optic cables
• Public network provided services

WIDE AREA NETWORK (WAN) TECHNOLOGIES

• Digital hierarchies, T1 and E1
• Packet switching
• Frame relay
• ATM
• SDH/sonnet

LOCAL AREA NETWORKS (LANs)

• Ethernet networks
• Industrial Ethernet
• TCP/IP
• LAN connectivity: bridges, routers and switches
• Redundancy options
• Web based Industrial SCADA
• Wireless
• OPC

MODULE 9: INTRODUCTION TO IEC 61131-3

• Concepts
• Common elements
• Programming languages: structured text
• Function block diagrams

MODULE 10: SCADA NETWORK SECURITY

• Introduction
• Authentication and encryption
• SCADA firewalls
• Firewall architectures and guidelines

TROUBLESHOOTING AND MAINTENANCE

• Troubleshooting SCADA systems
• Maintenance tasks

SPECIFICATION OF SYSTEMS

Common pitfalls, Standards, Performance criteria, Testing, Documentation and Future trends

MODULE 11: BUILDING A PLC PANEL, AS WELL AS GENERAL COMMISSIONING, TESTING AND UPGRADING

• Electrical design and construction
• Commissioning and installation
• Simulation and testing
• Problem isolation and faultfinding
• Upgrading of control systems

MODULE 12: INDUSTRIAL COMMUNICATIONS PROTOCOLS

• RS-232 interface standard
• RS-485 interface standard
• Fieldbus
• Modbus
• DNP3.0

MODEMS

• Introduction and principles
• Asynchronous/synchronous
• Modulation techniques
• Error detection and correction
• Troubleshooting

Please note: Course content is subject to change. Due to rapidly changing technology and based on feedback from students and instructors, the Engineering Institute of Technology courses are continuously being updated and improved.

Software/Hardware UsedSoftware

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Hardware

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