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DCS& PLC
First Line Maintenance
(5-Day
Practical Workshop)
REGISTRATION
INTRODUCTION
DCS VERSUS
SCADA VERSUS PLC’S
¨
Comparison
¨
The Smart
Instrument as a Key Component in a DCS System
DCS SYSTEM
ELEMENTS
¨
Describe
the main differences between a distributed control
system a DDC and a CSC system.
¨
Describe
the end elements to be catered for and their position in
a DCS
¨
Requirements of the operator interface within the DCS
¨
Identify
the layout of a DCS system with data highway
communications paths
THE BASIC
CONTROLLER (PLC)
¨
Introduction to PLC’S
¨
A brief
history of PLC’S
¨
Alternative
control systems – where do PLC’S fit in
¨
Why PLC’S
have become so widely accepted
¨
Lingering
concerns about PLC’S
¨
Block
diagram of typical PLC
¨
PLC
Processor Module – memory organisation
¨
Input /
output section – module types
¨
Power
Supplies
FUNDAMENTALS OF PLC SOFTWARE
¨
Methods of
representing Logic
o
Boolean
Algebra
o
Instruction
Code
o
Graphical
Presentation
§
Functional
Logic Diagrams
§
Ladder
Logic
¨
Fundamental
Ladderlogic Instruction Set
¨
Comparison
of different manufacturers
o
Memory and
Data Representation
o
Instruction
Code
USING
LADDERLOGIC FOR SIMPLE DIGITAL FUNCTIONS
¨
The Basic
Rules
¨
Comparison
with 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 De Morgan’s Law
USING
REGISTERS (WORDS)
¨
Number
Systems
¨
Types of
Register Data
¨
Timers
¨
Counters
¨
Bit Shift /
Rotate
¨
Table
Functions
¨
Register
(Matrix) Logic Functions
PRACTICAL
SESSION
GOOD
PROGRAMMING HABITS
¨
Keeping
track of addresses and data used
¨
Looking
ahead – how will programs be maintained
¨
Practical
methods to improve program quality
-
Organisation of code
-
Through
documentation
-
Simplifying
changes
PRACTICAL
SESSION
STANDARDIZED PROGRAMMING
¨
Block
Configuration
¨
IEC 61131-3
“open” Programming languages (structured text, function
block, ladder, sequential)
¨
Concepts
¨
Common
Elements
¨
Programming
languages: Structured Text
¨
Function
Block Diagrams
¨
Ladder
Diagrams
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Instruction
List
¨
Sequential
Function Chart
GOOD
INSTALLATION PRACTICE
¨
Location of
hardware
¨
Good wiring
practice
-
Cable
spacing
-
Power
distribution
-
Wire
numbering
¨
Reducing
Noise and Interference
¨
Screening
and shielding
¨
Earthing
and grounding
PRACTICAL
SESSION
ADVANCED
CONTROL WITH PLC’S
¨
The concept
of reusable Logic - Examples: Drive Logic, Alarm
handling
¨
Use of
advanced programming functions
¨
Matrix
logic
¨
Table
Functions and Indirect addressing
DATA
COMMUNICATIONS
¨
Overview of
DCS & SCADA Communications (field/operator/long
distance)
¨
Physical
Architectures
¨
Network
topologies
¨
Foundation
Fieldbus
¨
Profibus
¨
Devicenet
¨
Industrial
Ethernet
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Fast
Ethernet
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Routers,
switches, hubs
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TCP/IP
¨
Industrial
Network security
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Links to
MES and ERP
UNINTERRUPTED OPERATION AND SECURITY ISSUES
¨
Redundancy
in the DCS
¨
Security in
design and operation
THE
OPERATOR INTERFACE
¨
The
operators process ‘window’
¨
The
requirement for multiple video display units
¨
The various
operator display configurations
¨
The
requirement for keyboard entry of data
¨
The touch
screen data selection technique
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Ergonomic
requirements in the operator environment
ALARM
SYSTEM MANAGEMENT FOR DCS’S
¨
Philosophies of Alarm Management
¨
Design
Overview
-
Human and
Ergonomic Factors
-
Structure
of good Alarm System
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Safety
Integrity Level (SIL)
¨
Analyse the
Alarms
¨
Design of
Alarm System
¨
Measurement
of Performance
DISTRIBUTED
CONTROL SYSTEM REPORTING
¨
The
operation of advanced DCS by use of multi-screen
displays, cross screen invocation and linking
¨
Alarm
reporting, types of alarms generated and acceptance of
alarms
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The
different types of logs and reports which can be
configured on a DCS system
¨
Data
history use in logs, reports and trend displays
DISTRIBUTED
CONTROL SYSTEM CONFIGURATION
¨
The
organisation of system data files
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Data
configuration procedures necessary for setting up the
DCS area database
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The need
for multiple personalities attached to operator stations
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The need
for different security levels attached to various
operating parameters
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Configuration control procedures adopted to ensure data
integrity
MAINTENANCE
CONSIDERATIONS
¨
Maintenance
requirements of system and system elements
¨
The
requirements for in-built diagnostics and for
maintenance diagnostic routines
¨
The
requirements for installation of UPS system
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Recovery of
a DCS following a power outage
BATCH
PROCESSES AND SEQUENTIAL CONTROL
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Remembering
the program state
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Creating a
“stepper”
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Step
advance
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Fault
detection and recovery
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Operator
Intervention
¨
Multiple
recipes or alternate paths
¨
Sequential
function charts
PID CONTROL
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The
importance of timing and scan time
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When PID is
not always appropriate:
-
intermittent measurements
-
long
transport delays
SAFETY
PROGRAMMABLE SYSTEMS
¨
Why regular
PLCs should not be used for safety functions
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Programmable electronic logic solvers
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Safety
Certification
¨
Certified
programming systems
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Application
examples
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Growth of
networked safety devices & certified networks
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Integrated
safety systems
OPC
¨
Introduction to OPC
¨
What is OPC
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Architecture
SYSTEM
CHECKOUT AND TESTING
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Development
and verification of code
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Factory
acceptance testing
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Testing
procedures
¨
Emulating
missing hardware
¨
Emulating
process responses
SUMMARY &
OPEN FORUM
COMPLETE
FEEDBACK SHEETS
CLOSING
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