In this session, you will learn: PLC Components In depth understanding PLC hardware & Installation Preparing PLC signal list

1. Industrial Automation Training
Session 2 – PLC Hardware

2. Page 1Classification: Restricted
Agenda
• PLC Components
• In depth understanding PLC hardware & Installation
• Preparing PLC signal list

3. Page 2Classification: Restricted
Do you agree that Instrumentation is an art of playing with
Physical variables ??
How should we call it as science ??
Measurement
Manipulation
Control
Monitoring
Do you agree that Instrumentation is an art of playing with
Physical variables ??
How should we call it as science ??
Measurement
Manipulation
Control
Monitoring
PLC Cabinet
Cabinet
Power
supply
Relays
Terminal
blocks
Wiring
Input
Modules
Output
Modules
PLC
Controller

4. Page 3Classification: Restricted
Do you agree that Instrumentation is an art of playing with
Physical variables ??
How should we call it as science ??
Measurement
Manipulation
Control
Monitoring
Do you agree that Instrumentation is an art of playing with
Physical variables ??
How should we call it as science ??
Measurement
Manipulation
Control
Monitoring
Do you agree that Instrumentation is an art of playing with
Physical variables ??
How should we call it as science ??
Measurement
Manipulation
Control
Monitoring
PLC Engineering practices
• Interpretation of Process & Instrumentation diagram
• Derivation of IO signal
• Preparation of IO list
• Preparing engineering BOM
• Engineering
• Factory Acceptance Test
• Commissioning
• Site Acceptance Test

5. Page 4Classification: Restricted
Simple P&ID diagram

6. Page 5Classification: Restricted
Signal List from P&ID
Instrument list
• Level transmitter
• pH Analyzer
• Pressure gauges
Equipment list
• Coarse screen Variable Frequency
drive
• Motors
• Motorized valve
TO IO SIGNAL DERIVATION

7. Page 6Classification: Restricted
IO Summary & Engineering BOM

8. Page 7Classification: Restricted
IO Signal List
IO Signal list
I/O List
Base I/O
Count
I/O Count with
20% Spare
Channel
Density
No. of
modules
Total signals
offered
Digital Input 26 32 16 2 32
Digital Output 13 16 8 2 16
Analog Input 9 11 8 2 16
Total 48 59 6 64

9. Page 8Classification: Restricted
Engineering BOM
Sr. No Item Description UOM Total Qty
1 Controller Set 1
1 Digital Input Nos 5
2 Digital Output Nos 4
3 Analog Input Nos 3
4 Analog output Nos 0
1 Cabinet Nos 1
2 Power supply Nos 1
3 Relays Nos 29
4 Terminal blocks Set 226
PS
Controller

10. Page 9Classification: Restricted
Engineering BOM- PLC
Sr. No Item Description UOM Total Qty
1 Controller Set
1 Digital Input Nos
2 Digital Output Nos
3 Analog Input Nos
4 Analog output Nos
1 Cabinet Nos
2 Power supply Nos
3 Relays Nos
4 Terminal blocks Set
Redundant /
Non
Redundant
Relays are
for what
How do
we rate
power
supply

11. Page 10Classification: Restricted
Engineering BOM- SCADA
Well !! My PLC is ready !
It can control automatically.
How do I view it
Can I have one computer ???
1. One Computer to
monitor
2. One PC write logics
to control
1. Operator workstation
(Graphical
representation)
2. Engineering
workstation
3. Ethernet switch to
connect to controller

12. Page 11Classification: Restricted
PLC architecture
Engineering
Workstation
Operator
Workstation
PLC Cabinet
Network Switch

13. Page 12Classification: Restricted
Do you agree that Instrumentation is an art of playing with
Physical variables ??
How should we call it as science ??
Measurement
Manipulation
Control
Monitoring
Do you agree that Instrumentation is an art of playing with
Physical variables ??
How should we call it as science ??
Measurement
Manipulation
Control
Monitoring
PLC Cabinet
Cabinet
Power
supply
Relays
Terminal
blocks
Wiring
Input
Modules
Output
Modules
PLC
Controller

14. Page 13Classification: Restricted
Topics to be covered in next session
• PLC Components
• In depth understanding PLC hardware & Installation
• Preparing PLC signal list

15. Page 14Classification: Restricted
Thank you!