1.What are the main advantages of PLC?

Modular design High reliability Economy Size Ease of programming Rugged construction and designed to withstand vibrations,temperature,humidity,noise Ability to communicate with computer 2.What are the major areas of application of PLC? Sequence control,timing,counting,and data calculation Batch or continuous process control Precise position/motion control Open loop or feed back control ,process data acquisition and display

3.Write about the relay With the relay type,the signal from the PLC output is used to operate a relay and so is able to switch currents of the order of a few amperes in an external circuit.The relay isolates the PLC from the external circuit and can be used for both D.C and A.C.switching. Relays are how ever relatively slow to operate. 4.What are the three sizes of PLCs Small Medium Large 5.What is the general application of the PLC? PLCs are mostly applied in steel mills,paper and pulp plants,chemical and automotive and power plants. 6.Write the key factors in selecting a PLC? The key factor in selecting a PLC is establishing exactly what the unit is supposed to do.In general it is not advisable to buy a PLC system that is larger than current needs dictate.How ever,future conditions should be anticipated to ensure that the system is the proper size to fill the current and possibly future requirements of an application 7.Define memory Memory is where the control plan or program is held or stored in the controller.The information stored in the memory relates to how the input and output data should be processed 8.List the types of memories Read only memory(ROM) Random Access Memory(RAM) Program Read-Only Memory(PROM) Erasable Programmable Read only Memory(EPROM) Electrically Allocable Read Only Memory(EAROM) Electrically Erasable Programmable Read only Memory(EEPROM)

Magnetic Core Memory

9.Explain the functions of PLC input and Output modules Input interface modules accept signals from the machine and convert them in to signals that can be used by the controller Output interface modules convert controller signals in to external signals used to control machine or process 10.Expalin On delay and OFF delay timer ON delay timer: This increment while it receives power flow and resets to zero when power flow and resets to zero when power flow is stopped. The On delay timer will turn ON the output device after delay OFF delay timer: OFF delay timer increments while power flow is off and resets to zero when power flow is on. The Off delay timer will turn OFF the output device after delay. 11.What is a PLC? A programmable logic controllers are industrially hardened micro computers designed to replace electromechanical relays that perform discrete or continuous functions in a variety of processing plant and factory environments. 12.Why the term logic is used? The term logic is used because the programming is primarily concerned with implementing logic and switching operations 13.Write the operating principle of the logic controllers Input devices and output devices are connected to the PLC. The controller monitors the inputs and outputs according to the program stored in the PLC by the operator and controls the machine or process 14.Write about the architecture of PLC It consists of a CPU,memory,input/output circuitry.The CPU controls and processes all the operations with the PLC.It is supplied with a clock with a frequency between 1 and 8 MHz.It also has a bus system,memory and input/output units a system ROM for permanent storage,RAM for the users program and temporary buffers. 15.What happens when the power supply is switched off? When power supply is lost PLC will loose its programmed content. To prevent the loss of the programs,when the power supply is switched off,a battery is likely to be used in the PLC to maintain the RAM contents for a period. 16.Write about the input /output channels The input/output channels provide signal conditioning and isolation functions so that sensors and actuators can be generally directly connected to them without the need for other circuitry. Common input voltages are 5V and 24V.Common output voltages are 24 V and 240V 17.What are optoisolators Opto isolators are used with transistor switches to provide isolation between the external circuit and the PLC. They are used to provide isolation.

18.List out the programming languages in PLC Ladder Logic(LAD) Statement List(STL) Function block diagram(FBD) 19.What is mean by power flow in PLC? If there is electrical current flow through the relay contacts in a rung,the output relay coil will be turned ON.This is termed power flow in the ladder rung 20.List the part of PLC Central processing unit The input/output section Programming device 21.Define program ladder Program ladders are used to record and store the program or to load pre-programmed instructions in to the processor.There are two types of program ladders Magnetic cassette Disk recorder and electromagnetic modules 22.List three possible functions of a PLC programming device The programming device provides the primary mean by which the user can communicate with the circuits of controller. The programming device allows the user to enter, change, or monitor a PLC controller program 23.Explain the function of an optical isolator There are three main functions Separate the higher ac input voltage from the logic circuits Prevents damage to the processor due to line voltage transients. Helps to reduce the effect of electrical noise, which can pass entire operation of the processor 24.What is the function of processor in PLC? The processor reads the inputs, executes logic as determined by the application program, performs calculations, and controls the outputs accordingly. It controls the operating cycle or processor scan 25.List the relay type instructions Instruction set is composed of contact symbols so the ladder diagram language is also referred as contact symbology

26.List three possible functions of a PLC programming device? Easy to use programming equipment is an important feature of the PLC. The programming device provides the primary mean by which the user Can communicate with the circuits of controller.

The programming device allows the user to enter ,change, or monitor a PLC controller program 27.Explain the function of an optical isolator? There are three main functions . They are Separate the higher ac input voltage from the logic circuits. Prevents damage to the processor due to line voltage transients. Helps top reduce the effect to electrical noise which can pass entire operation of the processor. 28.List the conditions for drawing the ladder logic ? Contacts may be always inserted in the upper left . Coils must be inserted at the end of a rung. All contacts must run horizontally (i.e)no vertically oriented contacts. The contacts must be nested . Flow must be from left to right. Contact progression should be straight across. 29.List the sequence of operations carried out in PLC programming? Processor memory organisation Program scan PLC programming language Relay type instruction Instruction addressing Branch instruction Internal relay instruction Programming examine ON and OFF instructions Entering the ladder diagram. Modes of operation. 30.What is meant by program scan? During each operating cycle the processor reads all the inputs,takes their values and according to the user program energies or de_energies the output .This process is known as program scan. 31.What is meant by PLC programming languages? PLC programming languge refers to the method by which the user communicate information to PLC 32.List the relay type instructions? Instruction set is composed of content symbols so the ladder diagram langue is also referred as contact symbology 1.EXAMINE ON instructions 2.EXAMINE OFF instruction 3.OUTPUT ENERGISE 33.What is meant by internal relay instructions? Most PLCS have an area of memory allocated for what are known as internal storage bits .These storage bits are also called internal outputs ,internal coils,internal control relays are just internals .The internal outputs does not directly control an output device.

34.List the modes of operations in PLC? There are 5 different modes of operations .They are 1.Connect PLC with PC 2.Clering the Ram 3.Store the logic in the Ram 4.Run 5.Continous until stop mode is selected. 35.What are the applications of PLC? 1.Sequence control, timing, counting, data calculation 2.Batch (or)continuous process control 3.Pricise position/motion control 4.Open loop or feedback control ,process data acquisition and display 36.What are the word transfer instruction in Allen Bradley PLC5? Bit distribute(BTD) Move(MOV) Masked move(MVM) 37.What are the arithmetic operations ADD-addition SUB-subtraction MUL-Multiplication DIV-Division 38.What are the data comparison instructions Equal to-EQU Less than-LES Greater than-GRT 39.Name some program control instruction Master control relay-MCR Jump(IMP) Label-LBL 40.What are the three inputs in PLC sequencer function Step circuit Reset circuit Enable circuit 41.What are the uses of PC Maximizes plant yields Increases plant capacity and productivity Ensures the repeatability an the product quality Reduces raw material and energy costs Increases safety of plant operation and improved profitability 42.What are the applications of PC Electric oven temperature control

Reheat furnace temperature control of mill in an integrated steel plant Thickness and flatness control system for metal rolling Automation of hot strip mill in an integrated steel plant Control of Electric Power Generation plant 43.What are the uses of PLC Used for logic-based sequencing operations Used for counting, timing and complex mathematical operations Used to perform PID, feed forward and other control functions Large scale PLCs having data highway capabilities function well in DCS environment 44.What is PID PID stands for Proportional, Integral, Derivative controller. PID is an effective control system for continuous processes, that performs two control tasks. First PID control keeps the output at a set level even though varying process parameters may tend to cause the output to vary from the desired set point. Second, PID promptly and accurately changes the process level from one set point level to another set point level. 45. What is MCR? The master control relay (MCR) instruction is used in pairs to activate or deactivate the execution of a group of zone of ladder rungs. 46. What is JMP? The jump instruction (JMP) allows the normal sequential execution to be altered so the CPU will jump to a new position in the ladder program. 47. What LBL? The label (LBL) is to identify the Ladder rung that is the destination of a jump instruction. 48. What are the three subroutine instructions? 1.The jump to subroutine (JSR). 2.The Subroutine (SBR) 3.The return (RET) 49. What is EQU? The equal to (EQU) instruction is used to test whether two values are equal. 50. What is LES? Much like the equal to instruction, the less then (LES) instruction tests the contents of the value of one location (source A) to see if it is less than the value stored in a second location (source B). 51.Define SCADA? Supervisory Control And Data Acquisition system is computerized hardware and software based project that provides a single integrated view of all control and information resources, enable engineers, supervisors, managers, operators to view and interact with the working of an entire operation through graphical representation of their product process. 5 2.What is CIMPLICITY? CIMPLICITY is a SCADA package. It is based on a client-server architecture consisting of servers and viewers. Servers are responsible for the collection and distribution of data.

Viewers connect into servers and have full access to the collected data for viewing and control actions. 5 3.State the requirements of CIMPLICITY HMI plant edition? CIMPLICITY HMI Plant Edition provides an extraordinary selection of features that enables to configure comprehensive and robust project. It gives a quick tour which provides links to the related subject in the documentation. 5 4. What is a DDC? The DDC (Direct Digital Control) directly interface to the process for data acquisition and control purposes. 55. List the tasks performed by microprocessor in DDC? It reads the various variables from different transmitters through multiplexer and ADC. It determines the error for each control loop and executes control strategy for each loop. It outputs the correction value of control valve through DAC. 56.Mention the two algorithm used in DDC software? There are two algorithms for programming a three mode PID control loop Position algorithm Velocity algorithm 5 7.Define AI? Artificial Intelligence has been defined as the branch of computer science which deals with the software and hardware techniques to solve symbolic problems as against number crunching problems solved by EDP machines. 58.What is heuristics? The learned facts, experience and institution are three basic inputs which enable decision making collectively these are known as heuristics. In AI systems the decisions are taken on the basis of heuristics. 59.Mention the various categories under the AI system. Natural language system Perception system Expert or knowledge based system 60.List the various types of information presented to expert system. The information presented to the expert system may be factual, incomplete, judgmental, speculative, experimental, uncertain, fuzzy and intuitive. Expert system should derive conclusions based on such incomplete information just like real life human expert. 61.What is domain knowledge? The domain knowledge is stored in the knowledge base of system. The domain knowledge contains: Facts Relation between facts Heuristics 62.Differentiate the two reasoning mechanics.

Backward chaining:-stars with a goal i.e. conclusion which is most portable and then tries to go backward and match the left hand side of rule i.e. conditions. Forward chaining:-is a top down approach. It proceeds in the direction until the goal i.e. conclusion is reached. 63.List the goals for an ideal expert controller. Ability to control a large class of processes which may be time varying, non linear, with variety of disturbance. Requirement of minimum prior knowledge about the process. Ability to improve its performance with time, as it acquires more knowledge. 64.Differentiate between analog controller and digital controller. Analog controller though are faster than digital controllers, the later is preferred because the changes in the parameters values are possible in digital controller while not in analog controller. 65.List down the methodologies used in knowledge representation It includes Sematic networks In this,nods and arcs form graphical notation to represent objects and relationship among them Frames Frames are templates or modules for holding clusters of related knowledge about a particular narrow subjects Rules Rules may be in one of the three forms a)If {this happens} then do {that} or b)If(this is the case} then {that is true} or c) If { this is the case} then do {that} 66.What are the operational objectives that a control system is called upon to achieve? Ensuring the stability of the process Supporting the influence of external Optuimising the economic performance of a plant or A combination of the above 67.What are the main constituents of the fuzzy controller Fuzzifier Knowledge base Decision strategy Defuzzifier 68.What are the advantages of neural network? Good fit for non linear models Ability to adapt,generalize and extrapolate results Speed of execution in recall mode Ease of maintenance

69.What are the disadvantages of neural networks? Cannot handle constraints Cannot optimize Needs of lots of data Needs lots of CPU power in training session Are unpredictable for utilization in untrained areas 70.What is the important concept in fuzzy logic It is the grade of membership-A number which describes the extent to which an element is in a set.It also describes the truth value of a particular statement. 71.What is meant by membership function? The grade of membership of fuzzy set is defined by membership function.The membership function provides a direct linkage between fuzzylogic and fuzzy sets.It is defined by mA(x).Where x is a member of A and A is some proportional or predicate class. 72.What is fuzzy controller? A controller which is used to control the complex processes is to investigate the control stratergies followed by a human operator which are based on institution and experience. 73.What is mean by fuzzification In fuzzy controller,in order to include the control statergy of human operator the ensor readings which are non-fuzzy should be converted to fuzzy from by a process called fuzzification 74.What are the manipulated variables to be used to control the process Ususally in a process, there are number of inputs,variables adjusted freely.Which one we select to use as a manipulated variables is a crucial question,as the choice will affect the quality of control actions 75.What are the measure problems in velocity algorithm? Controller drift Integral overshoot 76 What is the significance of DCS? Used for interfacing and computing functions and also provides the means of communication between the other devices. It consists of local control unit, low level interface, high level interface, shared communication facility. Etc 77. Mention any two advantages of DCS more reliable small expensive cost is lower than centralized system which performs the same function. 78. What is LCU? Local control unit is the small collection of hard ware in the system that can do closed loop control. Local control unit interfaces directly to the process. 79. What is the significance of LLHI?

This is the device that allows the operator or instrumentation engineer to interact with the LCU to change set point, control modes, control configuration, or tuning using a direct connection. LLHI can also interface directly to the process. 80. What is the function of HLOI? It has the functions similar to the LLHI with increased capacity and user with increased capability and user friendliness. It interfaces to other devices only over the shared communication facilities. Operator oriented program at this level is called HLOI. It is an instrument engineer oriented program. 81. What is shared communication? One or more communication hardware and associated software that allow the sharing of data among all devices in the distributed system. Shared communication facilities do not include dedicated communication channels between specific devices. 82. What is the need can be satisfied in designing an industrial grade LCU? flexibility of changing the control configuration Ability to use the controller without being a computer expert. Ability to by pass the controller in case it fails. So that the process still can be controlled manually. Ability of the LCU to communicate with other LCUs and other elements in system. 83. What is the architecture parameter to be considered while selecting LCU? size of controller functionality of controller performance of controller communication channels out of controller Controller output security. 84. Compare the configuration of the controller Architecture parameter Controller size Configuration A Number of function needed for single PID loop or motor controller Uses both continues and logic function Configuration B Includes and I/O Configuration C

functions Equivalent to small DDC system

Controller functionality

Uses both continues Uses both continues and logic function and logic function Split between the controller

Controller scalability

High degree scalability

of Requires both Not scalability controller types

85. What are the security requirements of LCU? Maximize the availability of the automatic control functions of the system.

During failure of the controller allows the operator to take the manual control of that process? Operator can shut the process down in an orderly and safe manner. 86. Write objectives of DCS. 1. Safe operation of plant 2. Lowest cost of operation 3. Longest equipment life 4. Minimum environment effect 5. Maximum efficiency 87. What is distributed system? A distributed system is one in which components located at networked computers communicate and coordinate their actions only by passing messages. 88. What is DCS? A distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring.

89. Write benefits of DCS? High reliability reduce human error Improved response time allowing easier identification of bottle-necks Improve operator interface to plant better production scheduling, making maximum use of the production facilities Improve accessibility of plant data to engineering & management personals - Faster identification of faults in both product and processing machinery Historical storage & retrieval system. 90. Write DCS elements1. Local Control Unit: This unit can handle 8 to 16 individual PID loops. Data Acquisition Unit: Digital (discrete) and analog I/O can be handle. Batch Sequencing Unit: This unit controls a timing counters, arbitrary function generators, and internal logic. Local Display: This device provides analog display stations, and video display for readout. Bulk Memory Unit: This unit is used to store and recall process data. 91. Write DCS elements2. General Purpose Computer: This unit is programmed by a customer or third party to perform optimization, advance control, expert system, etc Central Operator Display: This unit typically contains several consoles for operator communication with the system, and multiple video color graphics display units

Data Highway: A serial digital data transmission link connecting all other components in the system. It allow for redundant data highway to reduce the risk of data loss Local area Network (LAN 92. What are the Advantages of DCS? Access a large amount of current information from the data highway. Monitoring trends of past process conditions. Readily install new on-line measurements together with local computers. Alternate quickly among standard control strategies and readjust controller parameters in software. A sight full engineer can use the flexibility of the framework to implement his latest controller design ideas on the host computer. 93. List the Modes of Computer control. 1. Manual 2. Automatic PID with local set point 3. Supervisory PID with remote set point (supervisory) 4. Advanced 94. What are the two methods that control the flow of data across communication links? 1) Stop and wait 2) sliding window 95. What is the mechanism of stop-and-wait flow control? In the stop and wait method of flow control sender sends one frame and waits for an acknowledgement before sending the next frame. 96. What is the mechanism of sliding window flow control? In the sliding window flow control; the sending of data is constrained by imaginary window that expands and contracts according to the acknowledgement received by the sender. 97. What does the term error control mean in the data link layer? Error control in the data link layer is based on the automatic repeat request which means retransmission of data in three cases: damaged frame lost frame, lost acknowledgment. 98. What is the mechanism of poll/select? A poll is sent to the secondary device by the primary to determine if the secondary has to send. The secondary can respond by sending a acknowledgement or a data frame. A select frame is sent from the primary device to the secondary device to tell the secondary to prepare to receive data. The secondary responds with an ACK or a NAK 99. Define protocol. A protocol in data communications is the set of rules or specifications used to implement one or more layers of the OSI model. 100. What are the two types of data link protocol? 1).Asynchronous protocol 2).Synchronous protocol

101. What is manual backup? In this case, each LCU is designed to implemented only one or two control loops , and reliable is placed on the operator to take over manual control in case of a failure of LCU. 10 2. What is redundant control mode? In this case, the LCU is backed up by another LCU that takes over if the primary controller fails. In this way, full automatic control is maintained even under failure conditions. 103. What are the approaches in designing a redundant LCU architecture? a) CPU redundancy, b) One-on-one redundancy, c) One-on-many redundancy, d) Multiple active redundancy. 104. What is meant by geographically centralized and geographically distributed control system? All the LCUs are located in a central equipment room area; it is called as geographically centralized control system. Each LCU is located in the plant area closest to the portion of the process that it controls. It is called as geographically distributed control system. 105. What is functionally distributed control system? Several LCUs are used to implement the functions required in controlling the process. Therefore it is called as functionally distributed control system. 106. What are multiple active controllers? In this case, several LCUs are active at the same time in reading process inputs calculating control algorithms and producing control outputs to the process. The multiple active approaches is designed so that a failure of one of the controllers does affect the automatic control function. 107. What are the redundant approaches of redundant controllers? The redundant architecture should be kept as simple as possible. There is a law of diminishing in redundancy design. At some point, adding more hardware will reduce system reliability. The redundant nature of the controller configuration should be transparent to the user that is the user should be able to deal with the system in the way as a non redundant one. 108. Mention the requirement of operator interface process monitoring process control process record keeping 109. What are the motivations for using LLOI? It provides an interface that is familiar to the operator trying to use panel board instrumentation. Less expensive Provide manual back up in the case if high level operator interface fails. 110. Explain about different types of operator display.

Plant display. Area display. Group display. Lop display. Graphic display. Trend display. Tabular display. 111. What is the function of engineering interface? system configuration operator configuration system documentation system failure diagnosis 112. What is data transparency? Data transparency in data communication means we should be able to send any combination of bits as data. The combination of bits as data is not confused with the control information. 113. Define BSC. Binary synchronous communication is a well-known character oriented protocol .BSC operates in half-duplex mode using stop and wait ARQ in a point to point or multipoint configuration. 114. What is bit stuffing? Bit stuffing is the process of adding one extra 0 whenever there are five consecutive 1s in the data. So that the receiver doesnt mistake the data for a flag. 115. What do you mean by HDLC? High-level data link control is a bit oriented data link designed to support both halfduplex and full-duplex communication over point-to point and multi point links. 116. How do the three HDLC frame types differ from one another? a)I-frame -for data transmission and control b)S-frame-control c)U-frame for control and management

117. What are the types of modes in HDLC? a) Normal response mode (NRM) b) Asynchronous response mode (ARM) c) Asynchronous balanced mode (ABM) 118. What is piggy bagging? Piggy backing means combining data to be sent and acknowledgement of the frame received in one single frame. 119. Name the four types of s-frames? a) Receive ready(RR) b) Receive not ready (RNR)

c) Reject (REJ) d) Selective reject (SREJ) 120. Name the five categories of U-frame. 1) Mode setting 2) Unnumbered exchanging 3) Disconnection 4) Initiation 5) Miscellaneous 1 21. What are the types of sliding window ARQ error control? 1) go-back-n 2) Selective reject 122.Distinguish X-modem and Y-modem? X-modem 1.the data is 128bytes 2one CANS signal is used to abort a transmission 3.CRC error checking is used 4.It is a half-duplex stop and wait ARQ protocol Y-modem 1.the data unit is 1024bytes 2.two CAN signals are used 3.ITU-T CRC is used for error checking 4.here multiple files can be sent simultaneously

123. What are the disadvantages of asynchronous transmission? 1).speed of transmission is less 2)It leaves unpredictable gaps of time between each character 3).the addition of start and stop bits and the insertion of gaps into the bit stream make asynchronous transmission slower. 124. What are the two types of synchronous protocol and explain it? 1) Character oriented protocol 2) bit-oriented protocol 125. What is routing table? A routing table has columns for at least three types of information: the network ID and ID of the next router. The network ID is the final destination of the packet. The cost is the number of hops a packet must make packet to get there. And the next router is the router is the router to which a packet must be delivered on its way to a particular destination.