Course Objectives

1. Design of PLC control panel and ladder Programming
2. Complying to the industry specifications, guidelines and safety standards during work.
3. Testing troubleshooting PLC panels
4. Installation and commissioning of PLC panels

Learning Outcomes

1. Identify the role and responsibilities of PLC technician.
2. Comply with the safety procedures and standards to be followed while working
3. Able to download and upload the program with minor changes through software.
4. Can identify the accessories used in the PLC panel and raise procurement.
5. Prioritizing activities and organizing resources to meet desired outcome.

Course Syllabus

Module 1:
Work organization and management and safety.
- Big picture
- Working safety measure and standards
- Machine safety.
- Department involve in installation and commissioning
- Quality standard system
- Presentation on safety and machine safety.
- Draw Hierarchy system of any product manufacturing company.
- Write the quality standards follows in industries (manufacturing product).

Module 2:
Detailing and procurement of PLC control panel.
- Technical specification and documentation(product manual)
- Procurement of components for PLC panel building
- Drawing analysis of control panel
- Component identification
- Preparation of the working schedule

Module 3:
PLC panel testing and troubleshooting.
- Basic of PLC with introduction
- Introduction to contacts (NO,NC and coil)
- Communication establishment of PC and PLC
- Contactor wiring and loop testing.
- FAT (FIELD ACCEPTANCE TEST)
- introduction to software
- Communication establishment of PC and PLC
- latching programming using NO,NC and coil
- Download and upload of the program
- Download and upload of the program with minor changes and troubleshooting in software.
- Contactor wiring and loop testing.

Module 4:
Commissioning of PLC panel
- Definition of commissioning
- Use of IECS Standards during the installation and commissioning.
- Customer hand over detailing:
Standard operating system(SOP)
General arrangement drawing(GA)
Piping and instrumentation diagram (P&ID)
- Installation of the panel on site with field devices I/Os
- Preparation of the signed report with the customer for panel commissioning on site.

Session Plan

Session 1

LECTURE – Big picture and description with importance of the job role
DEMO – Safety practices in the working environment
PRACTICE - Presentation on safety and machine safety

Session 2

LECTURE – Machine safety and basic maintenance
DEMO – The safety equipments and PPE with its proper uses.
PRACTICE – Machine safety schedule practice

Session 3

LECTURE – Department involve in installation and commissioning
DEMO – Creating the Hierarchy system of any product manufacturing company.
Web links:
Hierarchy of manufacturing plants

Session 4

LECTURE – Quality standard system
DEMO – the quality standards follows in industries (manufacturing product).

Web links:
Roles and Responsibility of Quality Assurance

Session 5

PRACTICE – Report on the quality assurance of the panel

Session 6

LECTURE – Technical specification and documentation(product manual)
DEMO – Procurement of components for PLC panel building

Web links:
Automation review Q&A

Session 7, 8

PRACTICE – Design a procurement format and rise your order as per GA.(general arrangement)

Session 9

LECTURE – Procurement of components for PLC panel building
DEMO – Introducing to the GA drawing with dimensions

Web links:
Electrical control Panel

Session 10, 11

PRACTICE – As per the GA drawing creating a control panel for customer in auto cad.

Session 12

LECTURE – Basic of PLC with introduction
DEMO – PLC to PC communication establishment

Web links:
Automation - The next future
PLC to PC communication

Session 13,14

PRACTICE – PLC to PC communication establishment
- Upload and download of program

Session 15

DEMO – testing the panel wiring with continuity test
- testing the power supply unit for the plc
- testing the digital I/O and analog I/O

Web links:
Control panel Testing
Trouble shooting of PLC program

Session 16

PRACTICE – practice the above testing in the tabular format provided

Session 17

LECTURE – FAT (field/factory acceptance test)
DEMO – Tolerances of the machine and highest working capacity
- challenges faced during testing of machine

Web links:
Factory acceptance test

Session 18, 19

PRACTICE – Note the effects and points during the checking of the machine parts.

Session 20

LECTURE – Commissioning of machine and with field devices
DEMO – field devices (sensors and actuators) available ,proper supply to the panel

Web links:
Interfacing sensors to PLC

Session 21, 22

PRACTICE - Installation of the panel on site with field devices I/Os

Session 23

LECTURE – IECS Standards during the installation and commissioning
DEMO – Customer hand over detailing:
Standard operating system(SOP)
General arrangement drawing(GA)
Piping and instrumentation diagram (P&ID)

Web links:
Piping and interfacing diagram
General Arrangement of Drawing
Standard operating Procedure
Standard for industrial control panel
Cable size according to IEC

Session 24

PRACTICE - Preparation of the signed report with the customer for panel commissioning on site

Session 25 - 30

Project

Project

Design of DOL starter using the PLC (ladder)
Design a PLC control panel for DOL (hardware)
Modification and troubleshooting to the Downloaded program (ladder)
Troubleshooting in the above given project
( fault to be generated by the trainer)