Programmable Logic Controllers & SCADA
Course Overview
This course provides an in-depth introduction to Programmable Logic Controllers (PLCs), focusing on the fundamental concepts, practical applications, and hands-on programming skills needed to design and troubleshoot PLC systems. The course combines theoretical lessons with practical exercises to ensure participants gain comprehensive knowledge and experience in PLC programming.
Who Should Attend:
• Engineers and Technicians: Electrical, mechanical, and industrial engineers or technicians looking to enhance their automation skills.
• Maintenance Personnel: Individuals responsible for the maintenance and troubleshooting of automated systems.
• Production Managers: Professionals overseeing automated production lines who need a better understanding of PLC systems.
• Students and Educators: Students studying engineering, automation, or industrial technology, and educators teaching these subjects.
• Professionals in Automation: Individuals working in industries like manufacturing, automotive, food processing, and any other sector where PLCs are used.
Objectives::
• Understand PLC Basics: Gain a foundational understanding of PLC hardware, architecture, and functions.
• Develop Programming Skills: Learn to write, debug, and troubleshoot PLC programs using industry-standard programming languages such as Ladder Logic, Function Block Diagram, and Structured Text.
• Apply Practical Knowledge: Apply theoretical knowledge through hands-on exercises and real-world case studies.
• Enhance Troubleshooting Skills: Develop skills to diagnose and resolve common issues in PLC-controlled systems.
• Understand Integration: Learn how PLCs integrate with other automation systems and devices, including Human-Machine Interfaces (HMIs) and SCADA systems.
Section 1
Course Outline:
Module 1: Introduction to PLCs
• Overview of Automation and Control Systems
• History and Evolution of PLCs
• Types and Applications of PLCs
Module 2: PLC Hardware
• Components of a PLC System
• Power Supplies, I/O Modules, and Communication Modules
• PLC Installation and Maintenance
Module 3: PLC Programming Languages
• Introduction to IEC 61131-3 Standards
• Ladder Logic Diagrams
• Function Block Diagrams (FBD)
• Structured Text (ST)
• Instruction List (IL) and Sequential Function Charts (SFC)
Module 4: Basic Programming Concepts
• Digital and Analog Signals
• Boolean Logic and Relay Ladder Logic
• Timers, Counters, and Comparators
Module 5: Advanced Programming Techniques
• Program Control Instructions
• Data Handling and Manipulation
• Advanced Functions and Function Blocks
• Networking and Communication Protocols
Module 6: Human-Machine Interface (HMI)
• Basics of HMI Design
• Integrating HMI with PLCs
• HMI Software and Configuration
Module 7: PLC Troubleshooting and Maintenance
• Diagnostic Tools and Techniques
• Common PLC Faults and Remedies
• Preventive Maintenance Practices
Module 8: Practical Exercises and Case Studies
• Hands-on Programming Exercises
• Real-world Application Case Studies
• Final Project: Design and Implementation of a PLC-Controlled System
Section 2
Siemens S7-300 and S7-400 PLCs
• Overview of Simatic s7 3000 and s7 4000
• Review hardware Installation, including Dialogue layer step 7
• Dialogue Layer Step 7: Network Configuration
Designing automation systems using Siemens S7-300 and S7-400 PLCs involves several steps, including planning, hardware setup, programming, and commissioning. Here’s a detailed guide on the process:
1. Planning and Requirements Gathering
• Define Objectives: Understand the automation requirements, process flows, control tasks, and performance criteria.
• System Architecture: Determine the overall architecture, including the number of PLCs, I/O modules, HMIs, communication networks, and interfaces with other systems.
2. Hardware Selection
• PLC Selection: Choose between S7-300 and S7-400 based on the complexity and scale of the application.
o S7-300: Suitable for medium to large applications with a moderate number of I/O points.
o S7-400: Ideal for large and complex systems requiring high processing power and a large number of I/O points.
• I/O Modules: Select digital and analog input/output modules based on sensor and actuator requirements.
• Power Supply: Ensure the appropriate power supply for the PLC and peripherals.
• Communication Modules: Select necessary communication modules for networking (e.g., Profibus, Profinet).
3. Hardware Configuration and Installation
• Mounting: Physically install the PLC, I/O modules, and power supply in the control cabinet.
• Wiring: Connect sensors, actuators, and communication cables to the respective I/O modules.
4. Programming/p>
• Software Tools: Use Siemens STEP 7 (TIA Portal) for programming.
• Programming Languages: Utilize languages like Ladder Logic (LAD), Function Block Diagram (FBD), or Structured Text (ST) based on the application and programmer preference.
• Develop Control Logic:
o Create program blocks (OBs, FCs, FBs) to implement the control logic.
o Define tags and variables for I/O points and internal data.
o Implement safety interlocks, alarms, and interlocks.
• Testing and Simulation: Test the control logic using simulation tools in TIA Portal to validate the functionality before deployment.
5. HMI/SCADA Integration
• HMI Development: Design HMI screens for operator interaction, status monitoring, and control using WinCC or other compatible HMI software.
• SCADA Integration: Integrate with SCADA systems for supervisory control and data acquisition if required.
6. Communication and Networking
• Network Configuration: Set up and configure communication networks (e.g., Ethernet, Profibus, Profinet).
• Addressing and Routing: Assign IP addresses and configure routing for communication between devices.
7. Testing and Commissioning
• Initial Power-Up: Power up the PLC and check for any hardware faults.
• Download Program: Transfer the control program from TIA Portal to the PLC.
• Field Testing: Test the system with actual field devices to ensure correct operation.
• Fine-Tuning: Adjust parameters and fine-tune the control logic as necessary.
8. Documentation and Training
• Documentation: Create detailed documentation of the system, including wiring diagrams, PLC programs, HMI layouts, and network configurations.
• Training: Provide training for operators and maintenance personnel on the operation and troubleshooting of the system.
9. Maintenance and Support
• Regular Maintenance: Establish a maintenance schedule for periodic checks and updates.
• Support: Ensure technical support for troubleshooting and resolving any issues that may arise during operation.
Additional Considerations
• Redundancy: For critical applications, consider implementing redundant PLCs and power supplies to enhance reliability.
• Safety: Implement safety PLCs and fail-safe modules where safety is a critical concern.
• Scalability: Design the system to allow for future expansion and scalability.
End of the Workshop
For Training arrangements call us on the detail below
TANZANIA: +255 749 50 26 78
SOUTH AFRICA: +27 694 31 79 73
KENYA: +255 749 50 26 78
DUBAI: +27 694 31 79 73
