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POWER PLANT INSTRUMENTATION PRACTICES Chapter no name: VII   Intelligent Control 

System  
                                                                                                            Section no: 2.1 PLC Types 

Section 2.1—PLC Types

2.1. PLC Types: In the previous section, discussions started with basics of PLC then slowly an
integration automation system based on PLC have been developed. During the discussions both
Hardware, Software, and operational aspects were touched upon. Here a short discussions have
been presented to classify the PLC types, so that the reader can select the type is needed for the
application.

2.1.1. Redundancy criteria: One of the way PLCs can be classified according to the redundancy.
Now the question is redundancy at which level. Redundancy can be at controller /CPU level and
or at the I/O level. Two perspectives are completely different.

1. I/O Redundancy discussions: In case of redundancy at I/O level then there are a few questions
arise whether both the Inputs or outputs shall be in One module/( or one chassis) or it can be
distributed to two different chassis/module. In the later case, one advantage is there that in case
the failure of one module will not result complete missing of the Input / Output. Also If one
Chassis is damaged ( say) due to fire, other shall be available. In case of Remote I/O such
distribution among two chassis may not be possible some time due to cost and complexity of
connection. After that the questions comes How the two Inputs /Outputs shall be handled in case
there is mismatch between two ( say—in one case there is snap of wire in out of the two inputs!).
Obvious answer is PLC need to monitor health of each channel and report in case of such event.
Still there may be difficulty in case NO types of contacts, because in that case same situation may
happen when there is wire snap as well as if the contact has not made( i.e. changed from NO to
NC). Whereas in case NC type i.e. power missing to detect the activation of contact such problem
is less! However there is another system where COC(Change over contacts). Where the contact
forms Central terminal changes over to other two contacts to form NO or NC contact. In such
cases all the three terminals are connected to the system and non coincidence error is
monitored( e.g. ISKAMATIC B of KWU control system). Now coming back to original
discussions, the question is at some place the voting circuit shall be there to select either of the
Redundant inputs! Obviously the voting circuit need to be built in the program. Similarly the
outputs coming out of the PLC need to be voted at some place before applying the same to the
actuator. Simple way to vote the two outputs to the actuators is to use diode auctioneering circuit
in hardware. In fig no. VII/2.0.3-2b redundant I/O systems in two chassis have been
shown whereas in fig no VII/2.0.3-2a same can be implemented in same chassis.
PLC

COC

Fig no. VII/2.1.1-1 Change over contact ( Non coincidence error detection)

2. CPU Redundancy discussions: Alike I/Os CPU or controllers there can be redundancies in
controllers as shown in fig no. VII/2.0.3-2b. Here the question is transfer of control of one to
other so that there will be no bump in the system in case of transfer of control as discussed in
Clause 2.0.3.2 in section 2.0 and nor repeated again..

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POWER PLANT INSTRUMENTATION PRACTICES Chapter no name: VII   Intelligent Control 
System  
                                                                                                            Section no: 2.1 PLC Types 

3. Communication redundancy Discussions: As shown in fig no VII/2.0.3-2a & b the system

buses may be redundant in nature to communicate data from various units over redundant bus.
Here communication over the bus is an important aspect, so that there is no mismatch between
the two. Also in some cases the routing of the physical bus may be done in two different path so
that in case of damage of one due (say) fire other can go on as it is! For two bus systems the
communication controllers shall be redundant to independently operate to continue uninterrupted
communication.

2.1.2. I/O connections: I/Os may be connected to the controller, also classify PLCs in to different
category: e.g.

• Directly( local I/O) (fig no VII/2.0.3-2a) or it can be an extension

• Remote I/O ( connected by communication link) (fig no VII/2.0.3-2a)

• Intelligent I/Os connected to the system over system Bus(fig no VII/2.0.3-2b)

• Intelligent I/Os connected via Field bus(fig no VII/2.0.3-3 a & b)

2.1.3. System Integration: Based of the need the from very small PLC a large integrated systems
can be integrated to accommodate a number of different control system. Also these integration
can be based on technological developments and systems as discussed clause no 2.0.3.3 in
Section 2.0.

2.1.4. Features: The various features of PLC have been discussed in clause no 2.0.2 in section2.0.
Based on emphasis of each of these factor will also vary the PLC types. Importance and criticality
of AVAILABILITY, DIGNOSTICS, SAFETY AND SECURITY of BMS /ATRS PLC is
beyond question when same is compared ( say ) with PLC in Raw Water pump. It does not mean
that the latter one is not important but less critical. This because in case of non availability of
BMS ?ATRS PLC whole plant has to trip. Naturally During selection importance will be attached
accordingly.

2.1.5. Hardware & Software aspect: these are also important to classify the PLC types. All the
Hardware and soft features discussed in Clause no 2.0.4 & 2.0.5 in Section 2.0 are not applicable
for all the PLCs. As the application is huge it is hardly possible to specify these in details here in
the book. Therefore from these are general specification, depending on application, specification
need to be framed so as to avoid Over/Under specification.

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