Practical Troubleshooting and Problem Solving of PLCs and SCADA Systems

Country: 
Malaysia
Category: 
Instrumentation
City: 
Shah Alam
Course Scheduled Number: 
140616
Workshop start date: 
Thursday, 26 June 2014
Workshop end date: 
Saturday, 28 June 2014

 

THE WORKSHOP

The objective of this workshop is to help you troubleshoot, identify, prevent and fix common PLC and SCADA problems. The emphasis is on practical hard hitting information that goes beyond typical theory, focusing unerringly on providing you with the necessary skills to solve your problems whether it is a PLC, SCADA system, or indeed communications system linking the two together. The automation system on your plant underpins your entire operation. It is thus critical that you have the knowledge and tools to quickly identify and fix problems as they occur to ensure you have a safe, secure and productive system. No compromise is obviously possible here. This workshop distils all the tips and tricks learnt over many years.

The first step in PLC troubleshooting is to decide if the problem is internal to the processor or in the I/O system. Experience shows that more than 80% of all PLC malfunctions come back to problems with I/O modules or field equipment (or indeed wiring). Problems that can be traced back to an I/O module (and specific input) are usually related to external field components; whilst internal PLC problems often result in large scale failure or erratic behaviour on the part of the PLC.

This workshop is designed to benefit you with hard-hitting practical up-to-date information on the application of PLCs for the automation and process control of plants and factories. It aims to give practical advice from experts in the field, to assist you with troubleshooting your PLC and SCADA systems.

The content of the workshop brings everyone up to date by briefly reviewing PLC and SCADA systems and then examining in a logical step-by-step fashion with hands-on exercises (both PLCs and simulation software to get to the problems quickly) PLCs and SCADA systems. The key industrial communications problems are briefly covered.

 

WHO SHOULD ATTEND?

  • Control engineers
  • Design engineers
  • Electrical engineers
  • Electricians
  • Instrumentation engineers
  • Instrumentation technicians
  • IT technicians and IT staff
  • Operators
  • Project engineers
  • Plant engineers
  • Trades staff working with PLCs
    And those who want to achieve good proficiency in troubleshooting their PLC and SCADA systems.

 

CONTENT SUMMARY

INTRODUCTION TO PLCS AND SCADA SYSTEMS

  • PLC block diagram of components
  • PLC processor module and memory organisation
  • PLC input/output modules
  • SCADA hardware
  • Power supplies
  • Good installation practice

FUNDAMENTALS OF PLC SOFTWARE

  • Methods of representing logic
  • Boolean algebra
  • Instruction code
  • Graphical representation: functional logic diagrams and ladderlogic
  • Ladderlogic instruction set (coils and contacts/timers/counters)
  • Advanced instructions (program flow/arithmetic/data transfer and PID)
  • Start-up/shutdown and fault routines
  • Good programming habits
  • Comparison of different manufacturers

SCADA SOFTWARE

  • Communication architectures
  • HMI interface
  • SCADA software blocks
  • SCADA alarm management

INDUSTRIAL DATA COMMUNICATIONS SYSTEM

  • Roadmap of different standards
  • RS-232/RS-485
  • Profibus and DeviceNet
  • Industrial Ethernet
  • TCP/IP
  • Modbus

BASICS OF TROUBLESHOOTING AND DIAGNOSING EQUIPMENT

  • Common symptoms, problems and solutions
  • How to quickly identify likely causes
  • Overall basic steps
  • Communications issues
  • Earthing, shielding and noise

PLC TROUBLESHOOTING ROAD MAP

  • Review of the key PLC troubleshooting issues

PLCS POWER AND EARTH

  • Visual inspection
  • Measuring voltages
  • Power supply test
  • AC ripple on DC power supplies
  • Batteries testing
  • EMI/RFI impacts
  • Earthing and screening/shielding

TROUBLESHOOTING PLC INPUTS/OUTPUTS

  • Internal memory status against the field activity
  • Digital input status
  • Output modules and power supply
  • Fuses
  • Forcing outputs ON and OFF
  • Leaky inputs and outputs
  • Isolation problems
  • You have located the problem - what to do now?
  • Tracking down intermittent problems

TROUBLESHOOTING PLC ANALOG INPUT/OUTPUTS

  • Isolated and non-isolated inputs
  • Ranges of analog inputs
  • Forcing analog output ranges
  • Filtering and isolation issues

MISCELLANEOUS HARDWARE ISSUES

  • Processor problems
  • What to do if you don't have the right replacement
  • Are you sure you have the right problem?
  • Confirmation that the system is indeed operating correctly
  • Other troubleshooting tips and tricks

PLC SOFTWARE ISSUES

  • How to return the program to its original state
  • Modifying an existing program
  • Modifying a program to trap problems

SCADA TROUBLESHOOTING ROAD MAP

  • Review of the key SCADA troubleshooting issues
  • SCADA system troubleshooting
  • PLC/SCADA interfacing problems

HUMAN MACHINE INTERFACE (HMI)

  • Configuration of database points
  • Troubleshooting I/O database

SCADA ALARM CONFIGURATION ISSUES

  • Configuration of alarms

SCADA TO PLC INTERFACE ISSUES

  • Drivers
  • Protocols
  • Throughput issues

KEY INDUSTRIAL DATA COMMUNICATIONS PROBLEMS AND TROUBLESHOOTING

  • Cabling and hardware (switches/routers/converters)
  • Fibre optics
  • Noise and interference
  • RS-485 issues
  • Industrial Ethernet
  • TCP/IP
  • Modbus

INSTALLATION AND COMMISSIONING

  • Control room
  • MCC requirements
  • Installation of equipment
  • Loop testing

TOOLKIT SUMMARY OF KEY PROBLEMS TO LOOK FOR

  • 23 common problems with PLCs and SCADA systems
  • What to do and how to fix them
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PriceRM2,850.00 MYR
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