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CURTIN UNIVERSITY

DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING

INSTRUMENTATION AND CONTROL 402


2nd Semester 2013
TUTORIAL SET 1
1.
a)

Determine the truth tables of the following ladder diagrams:


Y

b)

c)

e)

R1

R1

d)

R1

S1

S2

S2

S3

S1

S3

S1

S1

S2

S2

S3

S3

Y1

f)

R1

Y2

2.

The ceiling lights in a production plant are controlled by three separate switches
located at three different entry points. If they are controlled by a PLC and the
supporting relay system, write a ladder logic program for this controller such that
the lights can be switched on and off by any of the switch.

3.

Develop a PLC program for a fluid level controller of a tank. List and observe all
the essential steps to develop such complex and open ended PLC programs.

4.

In a long distance flammable gas pipeline the amount of gas is controlled by an


inlet valve. Three sensors (A, B, and C) located along the pipeline to monitor the
pressure of gas. Sensors generate discrete signals 0 or 1 (1 for normal and 0 for
high pressure). The operation of the inlet valve (Y1) is determined if all the
sensors are indicating the normal pressure. Determine the truth table for all
possible signals of the sensors A, B, and C and write a ladder program.
Historical experience show that sensors can fail. If only one of the sensors
fails the operation continues as normal. Determine the truth table when at least
two sensors are working as normal. Write a ladder program for this case.

The failure of one or two sensors is known as the sensor-disagreement.


Determine a truth table and write a ladder program for the sensor disagreement.
The sensor disagreement is shown by a blue warning light as the output Y2.
Write a complete ladder program for the operations of Y1 and Y2.
5.

Use 60-100 words to explain the followings:


a. What are the main components of SCADA?
b. Explain the steps to develop a SCADA application in for large operation
c. You are developing a SCADA system and you want to implement is
successfully, what are the major application considerations?
d. Why is Ethernet becoming so popular in industrial control systems?
e. Explain types, necessity and use of timers in PLC systems.
f. What do you need to consider for developing a successful PLC program?

Halit Eren

July, 2013

SOLUTIONS
A 1//
a)

b)
A
0
0
1
1

B
0
1
0
1

Y
1
1
1
0

A
0
0
1
1

B
0
1
0
1

Y
0
1
1
0

A
0
0
1
1

B
0
1
0
1

Y
0
0
0
1

A
0
0
1
1

c)

B
0
1
0
1

Y
1
0
0
0

d)
A
0
1

R1
0
1

Y
1
0

e)

f)
S1
0
0
0
0
1
1
1
1

S2
0
0
1
1
0
0
1
1

S3
0
1
0
1
0
1
0
1

Y1
0
0
0
1
0
1
1
1

Y2
0
1
1
1
1
1
1
0

A 2//
This problem is given to you in broad terms. As an engineer you need to consider the
process control requirements, the hardware and software, the cost and locations, etc.
a)

b)

Process description: Fluid tank FT is filled continuously. The fluid level


is controlled by a drain pump located at the output. Sensors are used to
monitor the level of the fluid. Safety, spillage, emergency shut-down are
the main concern.
Prepare control strategy: pump has two modes of operations
1. Automatic mode: when the level goes high the pump will start to drain
water until low level is reached
2. Manual mode: controlled by an operator

c)

Make a sketch of the process.

FLUID

HL

FLUID
LL

d)

Make a list of devices and their inputs and outputs connected to PLC.
Field Device
Manual/Automatic
Manual start button
Manual stop button
Fluid pump
Motor fault alarm
High Level (HL)
Low Level (LL)

e)

Remarks
For pump operation
To start pump
To stop pump
I/O commands
For annunciation
High-level switch
Low-level switch

Input
01
02
03
04
05
06

Output
01
01
-

PLC addresses
X001 (aut.), X002 (man.)
X003
X004
X005, Y001
Y002
X006
X007

Assign hardware configuration. The inputs/outputs of switches, sensor


inputs, high voltage inputs/output, and so on.

POWER
SUPPLY
REQUIR
g)

Output
01
02
-

Assign addresses to inputs and outputs


Field Device
Manual/Automatic
Manual start button
Manual stop button
Fluid pump
Motor fault alarm
HL
LL

f)

Input
01
02
03
04
05
06

CPU

ANOLO
G I/O

Develop Ladder Logic program

ASCII
MODUL

DIGITAL
I/O

FLUID LEVEL HIGH


X006

FLUID LEVEL LOW


X007

AUTO START
R001
AUTO START
R001
AUTO START
X001

AUTO START
R001

RUN OUTPUT
Y001

MANUAL MANUAL START


X003
X002

MANUAL STOP
X004
RUN OUTPUT
Y001
RUN OUTPUT
Y001

FLUID PUMP
X005

FAULT ALARM
Y002

TIME
R
1.5SE
RUN OUTPUT
Y001

FLUID PUMP
X005

Flowcharts, State designs, and Boolean logic diagrams.

HIGH LEVEL
HLS001 (X006)

AUTO START
(R001)

OR
AND

LOW LEVEL
LLS001 (X007)

AUTOMATIC
(X001)

MANUAL START
(X003)

AND
RUN OUTPUT
(Y001)
OR

MANUAL
(X002)
OR

AND

MANUAL STOP
(X004)

RUN STATUS
(X005)

AND
OR
AND

TIME
R
15

FAULT ALARM
(Y002)

A 3//
S1

S1

S1

S1

S2

S2

S2

S2

S3

LIGHTS

S3

Physical
PLC Logic
Operational
(Initial)
(Initial)
(Switch Closed)
0 0 0
0 0 0
1 1 1

S3

S3

A 4/
Question 1 Part f.
A 5/
Refer to books and lecture notes.

0 0 0

0 1 1

1 1 1

0 0 0

1 0 1

1 1 1

0 0 0

1 1 0

1 1 1

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