EI6702 Logic and Distributed Control System Department of EIE / ICE 2017-2018

UNIT I - Programmable Logic Controller

PART-A
1. Briefly explain about timers in PLC
The operation of time-delay relays is provided in software. The contacts are shown as NO or
NC designations. Only the address to the relay coil shows that it is a timer contact. The timer is
activated by a condition in a rung that leads to the timer being energized. Then the indicated time
delay (in seconds or minutes) is inserted before the associated contacts change state.
2. How do you choose the PLC for a particular application?
The selection of PLC based on
i) The number of input and output used ii) The control strategy
iii) Working environment of the system iv) Cost factor.
3. What is the difference between PLC and Computer?
The major difference between PLC and computer are,
1. PLC can accommodate industrial environment that will stand relatively high temperature,
humidity, moisture etc.
2. Programming of PLC is easier than Computer.
3. All the field point inputs and outputs are directly connecting to PLC. There is no need of
signal conditioning.)
4. What is latch? Where it is used?
Latch is a hardware or software device, which uses to maintain the state unless the next state
is generated. In PLC operations the relay contact need not be placed directly over the coil symbol, but
can go anywhere in the program with associated them with a particular coil.
5. What are the different methods in PLC programming?
The different methods of PLC programming are
i) Ladder program ii) Functional block diagram iii) Statement list.
6. Briefly explain about counters in PLC.
The counter works in a similar fashion as timer expect that it is counting of events that
determine when the associated contacts change state. Thus, if the counter is loaded with the number
10, after being energized 10 times the associated contacts will be changed. Counters can be
configured to count up, count down, count from preset values, and be reset before the count is
finished.
7. What are the advantages of PLCs?
a. Flexibility d. Lower cost
b. Implementing changes and correcting errors e. Simplicity of ordering control system
c. Large quantities of contacts components
f. Ease of changes by reprogramming
8. What are the disadvantages of PLCs?
a. Fail safe operation c. Environmental considerations
b. Fixed circuit and fixed program applications d. Newer technology
9. What is ladder diagram?
Ladder diagrams are the most commonly used diagram for non-electronic control circuits.
They are sometimes elementary diagrams or line diagrams. Sometimes they are considered a
subtype of schematic diagrams. The PLC program is look like ladder in a way. The program starts
at the top of the ladder and generally works down as our requirement.
10. How the scanning operation occurs?
All PLCs take a discrete amount of time to scan their operational programs completely. The
scanning takes place left to right across each rung and from the top to bottom rungs, in order.
Typically, the complete ladder scan time is a few milliseconds.
11. List the functions of PLC programming device.
The programming device is a device used to load the program into the processor. It can be a PC or
a dedicated piece of equipment made by the PLC manufacturer. It makes the PLC reprogrammable
and thus flexible.
12. What are the advantages of PLC timer?
The PLC timer the time may be programmable variable time as well as a fixed time. The
variable time interval may be in accordance with a changing register value. The PLC timer is that its
timer accuracy and repeatability are extremely high, since it is based on solid state technology.

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13. Name the classification of PLC based on size.
Small: It covers units with up to 128 Inputs/Outputs and memories up to 2K bytes. The PLCs
are capable of providing simple to advanced levels of machine control.
Medium: It covers units up to 2048 Inputs/Outputs and memories up to 32K bytes.
Large: Large PLCs, off course are the most sophisticated units of the PLC family. They have
up to 8192 inputs/outputs and memories up to 750K bytes. PLCs of this size has virtually unlimited
application.
14. Mention any 2 differences between PLCs and general purpose computers:
(i) PLC is designed to operate in the industrial environment with wide range of ambient
temperatures and humidity. A well-designed PLC is not affected by the electrical noise that is inherent
in most industrial locations.
The electrical noise and extreme temperatures affect computers.
(ii) PLCs execute a single program in an orderly and sequential fashion from first to last
instruction, whereas computers are complex computing machines capable of executing several
programs or tasks simultaneously in any order.
15. List the features of PLC.
The programmable controller has eliminated much of hand wiring associated with
conventional relay control circuits. It is small and inexpensive compared to relay based process
control systems. Programmable controllers also offer solid-state reliability, lower power consumption
and ease of expandability.
16. Draw the ladder diagram for double input timer.
Control line

Preset time
Time- based
Accumulated
time
Reset time

17. What is meant 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.
18. List the relay type instructions.
Instruction set is composed of contact symbols so the ladder diagram language is also referred
as contact symbology.
i) Normally Open instruction ii) Normally Closed instruction iii) Output coil instruction.
19. Enlist the advantages of PLC over relay ladder logic.
Relays PLC
They have to be hard-wires to perform a No hard-wire requirement.
specific function.
When the system requirements change, Can be easily changed or expanded.
the relay wiring has to be changed or
modified. Lower power consumption.
Higher power consumption.
20. Explain the function of 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 to reduce the effect of electrical noise, which can pass entire operation of the processor.
21. List the advantages of a PLC system over the traditional hardwired control system.
(Dec2013)
The programmable controller has eliminated much of the hard wiring associated with
conventional relay control circuits. It is small and inexpensive compared to equivalent relay-based
process control systems.
Increased reliability More flexibility Lower costs Communication capability
Faster response time Easier to troubleshoot.

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22. What is program scan?
During each operating cycle, the processor reads all the inputs, takes these values and
energizes or de-energizes the outputs according to the user program. This process is known as a scan.
A single PLC scan, which consists of the I/O scan and the program scan. Because the inputs can
change at any time, the PLC must carry on this process continuously.
23. List out any four PLC input and output devices. (May2013)
Input: i) Push button, ii) Limit switches, iii) Toggle switches iv) Pressure limit switch.
Output: a. Control relay b. Pilot lamps c. Solenoid d. Alarm.
24. Compare Ton and Toff timers. (Dec2013)
Ton timers Toff timers
When the coil is energized, the timed When the coil is de-energized, the timed
contacts are prevented from opening or contacts are prevented from opening or
closing until the time delay period has closing until the time delay period has
elapsed. elapsed.
When the coil is de-energized, the timed When the coil is energized, the timed
contacts return instantaneously to their contacts return instantaneously to their
normal state. normal state.
25. List the advantages of PLC over relay logic (May2014)
The programmable controller has eliminated much of the hard wiring associated with
conventional relay control circuits. It is small and inexpensive compared to equivalent relay-based
process control systems.
Increased reliability Communication capability
More flexibility Faster response time
Lower costs Easier to troubleshoot
26. How many configurations are there for PLC counter functions? (May2014)
Programmed counters can count up, down, or be combined to count up and down. The majority of
counters used in industry are up-counters; numerous applications require the implementation of down-
counters or of combination up/down-counters.
27. Write about rung and program scan. (Dec2014)
Rung: A group of programmable logic controller instructions which control an output or storage
bit, or performs other control functions such as file moves, arithmetic, and/or sequencer instructions.
This is represented as one section of a logic ladder diagram.
Program Scan: During each operating cycle, the processor reads all the inputs, takes these values
and energizes or de-energizes the outputs according to the user program. This process is known as a
scan. A single PLC scan, which consists of the I/O scan and the program scan. Because the inputs can
change at any time, the PLC must carry on this process continuously.
28. Mention the programming devices of PLC also write about the importance of optocoupler.
(Dec2014)
Programming Devices: The programming device provides the primary means by which the user
can communicate with the circuits of the controller. The programming device allows the user to enter,
change, or monitor a PLC controller program. Industrial CRT terminals are the most commonly
used devices for programming the controller. The CRT offers the advantage of displaying large
amounts of logic on the screen.
Mini programmers also known as hand held programmers are an inexpensive and portable
means for programming small PLCs.
Optocoupler: The optical isolator not only separates the higher ac input voltage from the logic
circuits, but also prevents damage to the processor due to line voltage transients. Optical isolation also
helps to reduce the effects of electrical noise, common in the industrial environment, which cause
erratic operation of the processor.
29. Give the specification for the PLC based on the following: (May2015)
(a) Name of PLC: Allen Bradley SLC -500 family
(b) Type of PLC: Large size PLC can handle up to 960 I/O points.
(c) Number of Input and Outputs: Up to 4096 Inputs and Outputs.
(d) Type of I/O: AC Inputs /Outputs, DC Inputs / Outputs, Relay outputs, Specialty modules.
(e) Speed of execution: up to 64K memory.

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30. Obtain the PLC equivalent for OR gate. (May2015)

The OR gate is essentially a parallel circuit that produces an output when any one contact is
closed.
31. What are all the programming devices available to program the PLC? (Dec2015/May2016)
PC: A personal computer (PC) is the most commonly used programming device.
Hand-held unit: Hand-held programming devices are sometimes used to program small
PLCs.
32. Define PLC? (Dec 2015/May/Dec2016)
Programmable Logic Controller (PLC) is a user friendly electronic computer that carries out
control functions of many types and levels of complexity. It can be programmed, controlled and
operated by a person unskilled in operating computers.
33. Sketch the timing diagram for ON Delay Timer. (Dec2016)

PART-B
1. (i) Explain the architecture of PLC. (6)
(ii) Design a PLC program and prepare a typical I/O connection diagram and ladder logic program
for the following counter specification.
Count the number of times a push button is closed.
Decrement the accumulated value of the counter each time a second push button is closed.
Turn on the light any time the accumulated value of the counter is less than 20.
Reset the counter to zero, when a selector switch is closed. (10) (Dec2016)
2. (i) Explain the functions performed by analog input and analog output modules of PLC. (6)
(ii) Illustrate function block programing with any sequential application of your choice. (10)
(Dec2016)
3. (i) Differentiate PLC and Conventional relay based logic system. (6)
(ii) Explain the functioning of analog and digital modules of PLC. (10) (Dec2015/May2016)
4. (i) Write down the steps to be considered for designing a 16 analog input and 5 digital input, 5
analog output and 2 digital output PLC.
(ii) What is the purpose of input status table and output status table in PLC and write any PLC
program using timer and counter applications.
(Dec2014/2015/May2016)
5. What are the functions of PLC CPU? Explain their operational sequences. (May2015)
6. (i) How many configurations are there in PLC counter functions? Explain. (8)
(ii) Draw a ladder diagram for fully automatic washing machine. (8) (May2015)

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7. (i) Explicate with an example advantages of PLC over relay logic (6)
(ii) Explain the analog and discrete I/O modules of PLC. (10) (Dec2014)
8. (i) Explain the function of following components of PLC. 1) CPU 2) Memory (8)
(ii) Construct a ladder and relay logic for a 4 input conveyor C has to run when any of the four
inputs is ON. Drive the necessary Boolean expression. (8) (May2014)
9. Use a PLC sequencer and timing. Explain the following dishwasher application.
(i) Soap release solenoid.
(ii) Input valve for hot water.
(iii) Wash impeller operation.
(iv) Drain water valve.
(v) Drain pump motor.
(vi) Heat element for drying cycle. (May2014)
10. (i) Explain how to convert the fundamental relay schematic diagrams into PLC ladder logic
diagram with an example. (8)
(ii) Design a PLC program to operate a light according to the following sequence
A momentary push button is pressed to start the sequence.
The light is switched on and remains ON for 2 sec.
The light is switched off and remains OFF for 2 sec.
A counter is incremented after this sequence.
The sequence then repeats for a total of 4 counts. (Dec2013)
After fourth count, the sequence will stop and the counter will be reset to zero. (8)
11. Draw the architecture of PLC and explain individual components. (Dec2013)
12. (i) How timers and counters are programmed in PLC? Illustrate with an example. (6)
(ii) Develop ladder diagram for controlling the level of liquid in a tank between upper and lower
limit. (10) (May2013)
13. (i) Explicate with neat block diagram power supply used for PLC (6)
(ii) Explain the architecture of PLC with neat diagram. (10) (Nov2012)
14. (i) Design a PLC program and prepare a typical I/O connection diagram and logic ladder program
for the following control specification
(1) To fill the tank with the liquid
(2) Heat the liquid to a particular temperature and stir the liquid.
(3) Maintain the temperature for 15 minutes.
(4) Empty the tank.
(ii) With an example explain programming counters in Ladder Logic Diagram.
15. (i) Draw the block diagram of an analog AC input module and explain.
(ii) It is required to a pilot light come on when all the following conditions are met:
3 out of 4 pressure switches must be closed.
All three limit switches must be closed.
The reset switch must not be closed.
Draw the relay and ladder logic diagram that will solve this hypothetical problem.
16. (i) Describe the architecture of a PLC.
(ii) Draw a ladder diagram for a three-motor system having the following conditions:
Motor 1 (M1) starts as soon as the start switch is on; after 10 seconds, M1 goes off and motor 2
(M2) starts. After 5 seconds, M2 goes off and M3 starts. After 10 seconds, M3 goes off. M1 starts
and the cycle is repeated.
17. (i) What is latching?
(ii) Design a ladder diagram that will control a stepper motor that it moves 10 steps forward, waits
for 20 seconds and then cause the motor to move 10 steps in the reverse direction.
18. (i) Draw the block schematic of a PLC showing its basic components and explain with block
diagram a typical ac interface input module.
(ii) Write a ladder program which could generate the following events to happen, with suitable
Input and Output connection diagram, when start push button is pressed the conveyor should be
started. Package in the conveyor should move up to the limit switch and stop. Whenever an
emergency stop switch is pressed, the conveyor motor should stop (immaterial of whether the
package has reached the position of limit switch). Red pilot light to indicate the conveyor is
stopped and green pilot light to indicate conveyor is running.
19. Develop the physical ladder diagram for a PLC that will perform each of the following function
when a NC push button is pressed.
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EI6702 Logic and Distributed Control System Department of EIE / ICE 2017-2018
i. Switch a pilot light on
ii. De-energise a solenoid
iii. Start a motor running
iv. Sound a horn
20. Prepare a ladder for the control problem shown below. The objective is to heat a liquid to a
specified temperature and keep it there for 30 min. assume suitable hardware. The event sequence
is:
i) Fill the tank.
ii) Heat and stir the liquid to the temperature set point and hold it for 30 min.
iii) Empty the tank.
iv) Repeat from step 1.
21. (i) Write about advanced PLC functions and alternative programming languages.
(ii) Assuming the process control applications where the input valve V in fills the tank till level-up
indicated by Lup is reached. Then start stirrer and keep it ON for 10secs. Open V out and empty the
tank till Le is reached. Develop logic ladder diagram.
22. Prepare a typical I/ O diagram and relay ladder diagram of the elevator with following sequences.
1. When the START push button is pushed, the platform is driven to the down position.
2. When the STOP push button is pushed, the platform is halted at whatever position it
occupies at that time.
3. When the UP push button is pushed, the platform, if it is not downward motion, is driven
to the up position.
4. When the DOWN button is pushed, the platform, if it is not upward motion, is driven to
the down position.

UNIT II - Applications of PLC

PART-A
1. What is ladder diagram? How is it useful in a PLC?
Ladder logic is a graphical language. The programmer draws a schematic diagram of logic on the
screen. This diagram is called as the ladder logic diagram and determines the sequence of operation
and ultimate control of equipment or machinery.
2. Distinguish between relay based PLC and computer based PLC.
Relay based: Slower switching speeds, needs more power to be energized, subjected to contact
arcing or welding, cannot be completely sealed, immune to false trips from electrical noise.
Computer based: Faster switching speeds, needs less power to be energized, not subjected to contact
arcing or welding, can be completely sealed, not immune to false trips from electrical noise.
3. List the sequence of operations carried out in PLC programming.
Processor memory organisation. Internal relay instruction.
Program scan. Programming examine ON and OFF
PLC programming language. instructions.
Relay type instruction. Entering the ladder diagram.
Instruction addressing. Modes of operation.
Brach instruction.
4. 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 are allowed.
The number of contacts per rung is limited.
Only one output may be connected to a group of contacts.
The contacts must be nested.
Flow must be from left to right.
Contact progression should be straight across.
5. What is meant by internal relay instruction?
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 output does not directly control an output device.
6. What is fail safe circuits?

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Some PLC circuits are programmed to be turned off by applying a signal voltage. For example the
latch-unlatch function requires an unlatch signal to turn the coil .If there is a loss control power,
pushing the stop button has no effect and coil remains on, since control power is needed for system
turn off, the emergency switch to stop machine where it is.
7. What are I/O scan and Program scan as applied to PLCs
The execution cycle starts with the hardware I/O system gathering the latest values of all input
signals and storing them in a fixed region of memory. This process is called the I/O scan. During the
program scan, new values of physical outputs, as determined from the various ladder rungs are
initially written into the output memory region and when the program is completed; all output values
are written to the physical output by PLC hardware in 1 operation.
8. What are the advantages of sequencer programming over conventional programming?
The advantage of sequencer programming over the conventional program is the large savings of
memory words. Typically, the sequencer program can do in 20 words what a standard program can do
in 100 words. By setting up a sequence of events, sequencers make programming simpler and any
future changes easier to make.
The sequencer output (SQO) instruction can be used to control output devices sequentially. The
desired sequence of operation is stored in a data file, and this information is then transferred
sequentially to the outputs.
9. What is the main advantage of JUMP instruction?
The advantages to the jump instruction include:
The ability to reduce the processor scan time by jumping over instructions not pertinent to the
machines operation at that instant.
The PLC can hold more than one program and scan only the program appropriate to operator
requirements.
Sections of a program can be jumped when a production fault occurs.
10. For the program shown below what is the status of PL1.

The status of PL1 of will be denergized.

11. Briefly explain the case study of PLC?
Bottle filling system is one of the applications of programmable logic control. It is possible for a
continuous control system to be part of a discrete-state process-control system. As an example, we
consider this experiment. The system consists of a conveyor on which the bottles are placed; the
conveyor motor is controlled by PLC. Periodically a bottle comes into position under the outlet valve
is opened and the bottle is filled. This requirement may be necessary to ensure a constant pressure
head during bottle filling.
12. What are the functional areas in which the programmable controllers are used in many
industries?
The PLC has been successfully used in many industries includes steel plant, paper and pulp
plants, Chemical, automotive and power plants. PLC performs a great variety of control tasks, from
repetitive ON/OFF control of a simple machine to sophisticated manufacturing and process control.
13. What advantage is there to the nesting of subroutines?
Nesting subroutines allow you to direct program flow from the main program to a subroutine and
then to other subroutine. Nested subroutines make complex programming easier and program
operation faster because the programmer does not have to continually return from one subroutine to
enter another.

14. Name the various sequence instructions used in PLC.

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Mechanical cam operated sequencer, Mechanical drum operated sequencer, programmed
sequencer.
15. Design a PLC ladder diagram to indicate light is to go ON when a count reaches 23 and go
OFF when a count reaches 31.

16. What are the limitations of using relay circuits for sequencing operation?
Separate hard wiring is required and one application can be adopted at a time.
17. What do you mean by relay logic?
The different symbols are followed for inputs and outputs unlike ladder logic.
18. What is SUBTRACT Instruction?
The SUBTRACT instruction is an output
instruction that subtracts one value from another
and stores the result in the destination address.
When rung conditions are true, the subtract
instruction subtracts source B from source A and
stores the result in the destination.

19. What is NEGATE (NEG) instruction?

The Negate (NEG) instruction is an output
instruction that negates (changes the sign of) of a
value.

When rung conditions are true, the negate

instruction changes the sign of source A and
stores the result in the destination.
20. Explain how the limit test (LIM) instruction compares data.
The limit test instruction (LIM) compares a test value to values in the low limit and the high limit.
The limit test instruction is said to be circular because it can function in either of two ways.
If the high limit has a greater value than the low
limit, then the instruction is true if the value of
the test is between or equal to the values of the
high limit and the low limit.

If the value of the low limit is greater than the

value of the high limit, the instruction is true if
the value of the test is equal to or less than the
low limit or equal to or greater than the high
limit .
21. What is MCR instruction?
The master control reset (MCR) instruction can be programmed to control an entire circuit or to
control only selected rungs of a circuit. When the MCR instruction is false, or de-energized, all non-
retentive (nonlatched) rungs below the MCR will be de-energized even if the programmed logic for
each rung is true. All retentive rungs will remain in their last state. The MCR instruction establishes a
zone in the user program in which all non-retentive outputs can be turned off simultaneously.
Therefore, retentive instructions should not normally be placed within an MCR zone because the
MCR zone maintains retentive instructions in the last active state when the instruction goes false.
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22. Mention any four real time applications of PLC. (May2013)
Sequence control, timing, counting, and data calculation.
Batch or continuous process control.
Precise position / motion control.
Open loop or feedback control, process data acquisition and display.
23. State the various math instructions in PLC. (May2013)
ADD: adds source A to source B and stores the results in destination.
SUB: subtract source B from source A and stores the results in destination.
MUL: multiplies source A by source B and stores the results in destination.
DIV: divides source A by source B and stores the results in destination.
24. State the purpose of program control instructions. (Dec2013)
The program control instructions are used to perform a series of conditional and unconditional
jump and return instructions. These instructions allow the program to execute sections of the control
logic if certain conditions are met.
25. Give examples for sequencer instructions and define. (Dec2014)
Sequencer: A mechanical, electric, or electronic device that can be programmed so that a
predetermined set of events occurs repeatedly. The various sequencers are mechanical cam operated
sequencer; Mechanical drum operated sequencer and programmed sequencer.
Examples: Dishwashers and traffic light control.
26. Write a simple program using relay ladder logic to implement traffic light control system.
(Dec2014)

27. Write differences between PC and PLC. (Dec2013/May2014)

PC PLC
It cannot be used in industrial environment.
PLC is designed to operate in the industrial
environment with wide ranges of ambient
temperature and humidity.
Computers are complex computing PLCs execute a single program in an
machines capable of executing several orderly and sequential fashion from first to
programs or tasks simultaneously. last instruction.
Hardware and software designed are not Hardware and software of PLCs are
much easily understandable by plant designed for easy use by plant electricians
technicians. and technicians. It is programmed in relay
ladder logic.
28. List some standard manufacturer PLCs available in the market. (May2014)

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Allen Bradley, Siemens, General Electric Fanuc, ABB, Omron, Toshiba, Yokogawa, Gould
Modicon, Texas Instruments, Square D and Telemechanique.
29. What is scan cycle in PLC? (May2015)
During each operating cycle, the processor reads all the inputs, takes these values and energizes or
de-energizes the outputs according to the user program. This process is known as a scan. A single
PLC scan, which consists of the I/O scan and the program scan. Because the inputs can change at any
time, the PLC must carry on this process continuously.
30. Compare the difference between event driven and time driven sequencer. (May2015)
An event driven sequencer operates similarly to a mechanical stepper switch that increments by
one step for each pulse applied to it.
A Time driven sequencer operates similarly to a mechanical drum switch that increments
automatically after a preset time period.
31. Give an example for program control instruction. (Dec2015)
The program control instructions are used to perform a series of conditional and unconditional
jump and return instructions. These instructions allow the program to execute sections of the control
logic if certain conditions are met.
Example: MCR- Master Control Reset instruction, JMP-Jump instruction, RET-Return instruction.
32. Define the instruction used for ON Delay timer operation in PLC. (Dec2015)
The ON delay timer operates, when the rung containing the timer is true, starts counts time
base intervals when the instruction is true.
33. Design a program that will convert Celsius to Fahrenheit conversion. (Dec2016)

34. Explain the use of sequencer instruction. (Dec2016)

Sequencers are used whenever a repeatable operating pattern is required. Sequencers are used for
control of dishwashers, material handling mechanisms, mechanical presses, packaging machines,
rotary tables, and in many other applications where accurate, repetitive, and sequential operations are
required in control circuitry.
35. Write the format of multiply and divide instructions. (Nov2012/May2016)
The MULTIPLY instruction is an output instruction that multiplies two values and stores the
result in the destination address. When rung conditions are true, the multiply instruction multiplies
source A by source B and stores the result in the destination.
The DIVIDE instruction divides the value in source A by the value in source B and stores the
result in the destination and math register. If the reminder is 0.5 or greater, a round-up occurs in the
integer destination. The value stored in the math register consists of the unrounded quotient (placed in
the most significant word) and the remainder (placed in the least significant word). Some larger PLC's
support the use of floating-decimal as well as integer values.
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36. Write a simple program using PLC to implement the EXOR logic gate. (May2016)

PART-B
1. (i) Develop the ladder logic diagram for liquid level control application. (10)
(ii) How to use a PC as a PLC? (6) (May2016)
2. (i) Mention the inputs and outputs used in a bottling application and write a program using RLL.
(ii) Wrte a PLC ladder diagram for a process application of your choice. Mention the I/Os.
(May2016)
3. (i) Illustrate the advantage of jump instruct with an example of your choice. (6)
(ii) Write a program that will cause a light to come ON if a PLC counter value is less than 10 or
more than 30. (10) (Dec2016)
4. (i) What do data manipulation instructions allow the PLC to do? Illustrate an example. (6)
(ii) Two part conveyor lines A and B feed a main conveyor line M. A third conveyor line R,
removes rejected parts a short distance away from the main conveyor. Conveyors A, B, and R have
parts counters connected to them.construct a PLC program to obtain the total parts output of main
conveyor M. (10) (Dec2016)
5. Describe any typical control application using math instructions of PLC. (Dec2015)
6. (i) Mention the inputs and outputs used in a bottling application and write a program using ladder
diagrams (use minimum 6 I/O, 2 Timers, and 1 Counter).
(ii) Can a PC be used as PLC? How? (Dec2015)
7. (i) Explain basic comparison function of a PLC. (8)
(ii) Design a ladder diagram that will control a stepper motor so that it rotate 10 steps forward,
waits for 20 seconds and then causes the motor to rotate to steps in the reverse direction.
(May2015)
8. Write a PLC program to implement the process illustrated below. The sequence of operation is
to be as follows:
(i) Normally open and normally closed push buttons are used to start and stop the process.
(ii) When the start button is pressed, solenoid A energizes to start filling the tank.
(iii) As the tank fills, the empty level sensor switch closes.
(iv) When the tank is full, the full level sensor switch closes.
(v) Solenoid A is de-energized.
(vi) The agitator motor starts automatically and runs for 3 min to mix the liquid.
(vii) When the agitator motor stops, solenoid B is energized to empty the tank.
(viii) When the tank is completely empty, the empty sensor switch opens to de- energize
solenoid B.
(ix) The start button is passed to repeat the sequence. (May2015)
9. (i) Mention the inputs and outputs used in a bottling application and write a program using relay
logic (use minimum 6 I/O, 2 Timers, 1 Counter). (8)
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(ii) Write a PLC ladder diagram for a process plant. Assume total of 5 inputs and 6 outputs.
Mention the I/Os. (8) (Dec2014)
10. (i) Classify the types of instructions in PLC and mentions its uses. (10)
(ii) How to use a PC as a PLC Explain with an example. (6) (Dec2014)
11. Discuss various program control instructions used in PLC programming. (May2014)
12. Write the ladder program for star-delta starter of induction motor. (May2014)
13. Describe the function of program control instructions and develop a program to illustrate their use.
(Dec2013)
14. Construct a PLC program to illustrate the bottle filling process. (Dec2013)
15. Discuss the automatic bottle filling system with hardware and ladder diagram. (May2013)
16. Develop a ladder diagram for the case given. A switch will increment the counter on when
engaged. This counter can be reset by a second switch. The value in the counter should be
multiplied by five and then displayed as a binary output. (May2013)
17. (i) Develop the logic ladder diagram for liquid level control application. (10)
(ii) How to use a PC as a PLC? (6) (Nov2012)
18. (i) Mention the inputs and outputs used in a bottling application and write a program using RLL.(8)
(ii) Write a PLC ladder diagram for a process application of your choice.
Mention the I/Os. (8) (Nov2012)
19. (i) Discuss the use of math instructions of PLC for automatic control of upper and lower set point
limits.
(ii) With an example, explain function block programming for sequence control application.
20. (i) Explain how hardware-to-program interface and program-to-hardware interface are established
in a PLC.
(ii) Propose and explain a safeguard technique for diagnosing failure in the I/O unit of a PLC
21. (i) For the following problem develop PLC ladder logic diagram.
A bottling process for 10 bottles operates as follows: Bottles are counted until all 10 are in position
for filling, when in position in the carton the 10 bottles are filled simultaneously for 5 seconds.
After filling there is a pause for 2 seconds for foam to subside, the 10 caps are then put on and
counted as they are installed. A solenoid then pushes the completed carton of 10 on to a conveyor.
The system is reset for a new group (to be restarted manually) of 10 bottles by a limit switch that
indicates that the carton is out of the fill position and on the conveyor.
(ii) Comment on the use of PC as PLC.
22. (i) Develop a logic ladder program for the bottle filling process with Bottle filling value (BFV),
Tank filling value (TFV), conveyor motor, Bottle full sensor (BF), Bottle position sensor (BP), a
Start Push Button and Stop Push Button.
(ii) Comment on program control instructions.
23. (i) Sketch the functional blocks of the different logical instructions supported by a PLC.
(ii) Design the input/output wiring diagram and logical ladder diagram for the following
application.
A thumbwheel switch gives temperature set point. A thermocouple is used to read the temperature.
Design an ON-OFF controller for controlling heater with differential gap of 20 C.
24. (i) What is the need for program control instructions? Illustrate with examples.
(ii) Design the ladder diagram for bottle filling system. State the assumptions made in the design.
25. Prepare a typical I/O connection diagram and develop relay and logic ladder diagram for a bottle
filling system.
26. Design a PLC Ladder program which converts the measurement of temperature in 1) Fahrenheit to
Celsius and 2) Celsius to Fahrenheit to Celsius.
27. Design a PLC Ladder program for an automatic ON/OFF controller with differential gap of + 1%
of set point.
28. Develop a PLC program for the following bottle process for 12 bottles,
* Bottles are connected until all 12 are in position for filling
* When in position in the carton, the 12 bottles are filled simultaneously for 7 sec.
* After filling, there is a pause of 4 sec for foam to subside.
* The 12 caps are then put on and counted as they are installed
* A solenoid the pulses the complete carton of 12 on to the conveyor.
* The system is reset for a new group (to be restarted normally) 12 bottles by a limit switch,
that indicates the carton is out the FILL position and on the conveyor.

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UNIT III - Computer Controlled Systems

PART-A
1. State differences between supervisory control and DDC.
When the digital computer has assumed all control actions of a conventional controller, it is called
as direct digital control. The only analog elements left in the process control are the measurement
functions and FCEs. The computer is used to change the SPs or the values of adjustable control
parameters of the local controllers in a supervisory control. This supervises many local DDCs
through I/O interfaces.
2. Why is it very difficult to use a computer for process control without a real time clock?
Real-time clock keeps track of the real worlds time and allows the computer to schedule its
functions at time intervals in co-ordination with various needs of the real world. Thus it is the real
time clock that determines when the computer should take data from measuring sensors or change the
values of the manipulated variables.
3. Name the functional units in computer control of processes.
CPU, Memory, Mass storage, Communication peripherals, I/O interface.
4. Why is the digital control necessary in industries?
Digital Control is a user friendly that carries out control functions of many types and levels of
complexity. It can be programmed, controlled and operated easily.
5. What is the need for watch dog timer in a process control computer?
WDT allows the computer to determine if control program is being executed smoothly or if the
program is hung up in a never-ending loop. In the second case an alarm alerts the operator that the
computer has lost control of the process, due to software problems.
6. Differentiate between analog controller and digital controller.
Analog controllers are faster than digital controllers, the latter is preferred because the changes in
the parameter values are possible in digital controller while not in analog controller.
7. Briefly explain about Data Acquisition System.
Data Acquisition System is generally a process of collecting input signal in analog or digital
form as rapidly, as accurately, completely, and economically as necessary and possible. It is used for
the measurement and processing of plant signal data before it is displayed on the operator desk or
permanently reordered. It can be of two types: i) Analog data acquisition system and ii) Digital data
acquisition system. Analog data acquisition system deals with information in analog form where as
digital data acquisition system handles information in digital forms.
8. Draw the general block representation of a computer control system?

9. What are the basic functions of computer control system?

The basic functions of computer aided process control system are:
Measurement and acquisition.
Data conversion with scaling and checking.
Data accumulation and formatting.
Visual display.
Comparing with limits and alarm raising.
Recording and monitoring of events, sequence and trends.
Data logging and computation.
Control action.

10. What is data logger?

A provision is made for assigning of a number of printers at the unit level for logging functions.
It is also possible to select any printer for any type of log that can be initiated on demand times.
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11. Mention two algorithms used in DDC software?
There are two algorithms for programming a three mode PID control loop
Position algorithm
Velocity algorithm
12. 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.
13. Briefly explain about Remote Terminal Unit (RTU).
The Remote Terminal Units (RTU) are basically distributed SCADA based systems used in
remote locations in applications like oil pipelining, irrigation canals, oil drilling platforms etc.
They are rugged and should be able to work unattended for a long duration. There are two modes
in which Remote Terminal Units work; i) Under command from central computer and ii) Stand
alone mode.
14. List out the task of computer control systems.
Field level (level-0) Plant level (level-3)
Control level (level-1) Corporate level (level-4)
Supervisory level (level-2)
15. Mention the various functionality of SCADA.
Access Control Alarm Handling Automation
MMI Logging/Archiving
Trending Report Generation
16. Compare SCADA and DDC. (Nov2012)
SCADA: When the computer is used to change only the SPs or the values of adjustable control
parameters of local controllers, the resulting system is Supervisory control.
DDC: When the digital computer has assumed all control actions of a conventional controller, it
is called as direct digital control.
17. List various SCADA manufactures.
Allen Bradly : RS View KPIT : ASTRA
Siemens : win cc Intelution : Aspic
Gefanc Wonderware : Intouch
18. Define SCADA. (May2013)
Supervisory Control And Data Acquisition (SCADA) 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.
19. List the tasks performed by microprocessor in DDC? (May2013)
It reads the various process variables from different transmitters through multiplexer and
ADC.
It determines the error for each control loop executes control strategy for each loop.
It outputs the correction value of control value through DAC.
20. What is SCADA? Give any four editors available in SCADA packages. (Dec2013)
Supervisory Control And Data Acquisition (SCADA) 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.
SCADA generally refers to industrial control systems (ICS): computer systems that monitor and
control industrial, infrastructure, or facility-based processes.
21. What are the major functions of data acquisition system? (Dec2013)
Transducers: For measurement of physical plant parameters such as temperature, pressure,
flow, etc.
Signal conditioning: Bring the signal level up to a sufficient value to make it useful for
conversion, processing, displaying and recording.

22. What facilities are provided in SCADA for handling trend data on the screen? (May2014)
CRT controller sub-module interfaces main processor to Visual Display Unit, which is used to
show the status of process by displaying transducers values, present set points entered through
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manual entry sub-module, historical trend of various parameters, mimic diagram of process, alarm
status etc. All the above display tasks are provided in the main processor through software.
LED/LCD control sub-module interfaces array of LED/LCD to main processor. Alarm annunciator
controller sub-module generates ON-OFF signal for each type of alarm.
23. What is Direct Digital Controller? (May2014)
The DDC (Direct Digital Control) directly interfaces to the process for data acquisition and
control purpose. That is, it has necessary hardware for directly interfacing (opto-isolator, signal
conditioner, ADC) and reading the data from process. It should also have memory and arithmetic
capability to execute required P, P + I or P + I + D control strategy. At the same time, the interface to
control valve should also be part of DDC.
24. Write about Tag and mention its uses. (Dec2014)
Tag numbers are letters and numbers placed within or near the instrument to identify the type
and function of the device.
25. Compare PLC and SCADA. (Dec2014)
PLC is a user friendly electronic computer that carries out control functions of many types and
levels of complexity. It can be programmed, controlled and operated by a person unskilled in
operating computers.
SCADA 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.
26. What is supervisory control? (Dec2015)
When the computer is used to change only the SPs or the values of adjustable control parameters
of local controllers, the resulting system is Supervisory control.
27. What are the features of SCADA system? (May2015/May2016)
Dynamic process Graphic Security (Application Security)
Alarm summery Data base connectivity
Alarm history Device connectivity
Real time trend Scripts
Historical time trend Recipe management
28. Mention the components used in SCADA system. (Dec2015)
Master-Main Terminal Unit (MTU), Remote Terminal Units (RTU), Human-Machine Interface
(HMI), SCADA Communications, and Field instrumentation.
29. Give any four editors available in SCADA package. (May2015/May2016)
Supervisory Control And Data Acquisition (SCADA) 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.
The various editors available in SCADA package are,
Access Control, MMI, Trending, Alarm Handling, Logging/Archiving, Report Generation,
Automation.
30. Compare DDC and DCS. (Dec2016)
DDC : Direct Digital Control is a universal controller where both analog and digital
input/outputs are combined in one controller card also it is specially designed for the HVAC ( Heat
ventilation air conditioning) design which are used for air handling unit. It's cost is lower than
compare to PLC and DCS, it uses profibus and modbus as a communication protocol which are very
speedy responds.
DCS : Distributed Control System which works on multiple controller, and number of controllers
are attached with system. Its cost is very high, communication protocols are open. It is mainly used
in continuous plant and very highly efficiency plant.
31. Write the functions performed by remote terminal unit. (Dec2016)
Remote terminal units, also known as (RTUs), connect to sensors and actuators in the process,
and are networked to the supervisory computer system. RTUs are "intelligent I/O" and often have
embedded control capabilities such as ladder logic in order to accomplish boolean logic operations.

PART-B
1. Distinguish between SCADA and DCA, and explain the hardware architecture of SCADA.
(May2016)
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2. Explain the direct digital control structure with a neat diagram and compare the advantages of
DDC over conventional analog controllers. (May2016)
3. (i) Explain in detail, with necessary diagram the architecture of SCADA. (12)
(ii) Write short ntes on communication architecutres in SCADA. (4) (Dec2016)
4. (i) Describe the merits and limitations of direct digital control. (10)
(ii) Compare DDC with SCADA. (Dec2016)
5. (i) Describe about direct digital control systems with examples. (10)
(ii) Explain the protocols used in the computer controlled systems and mention its standards. (6)
(Dec2014/2015)
6. Explain the components and architecture of SCADA with neat diagram. (Dec2015)
7. With a neat illustration explain the components and functions of SCADA system. (May2015)
8. Describe SCADA system used in Power Plant with a neat diagram. (May2015)
9. Explain the architecture of SCADA with neat diagram. (Dec2014)
10. Draw a neat diagram of SCADA system and explain the function of RTU. (May2014)
11. Describe any one application of SCADA with neat diagram. (May2014)
12. With neat block diagrams, explain the basic building blocks of computer controlled system.
(May 2013)
13. (i) Explain any one supervisory control scheme.
14. (ii) Compare DCS and DDC. (May2013)
15. Explain the functions of Data acquisition system.
16. (i) Explain the need for a computer in a control system.
(ii) With the help of neat schematic diagram, explain the function of Direct Digital Control of
a process.
17. (i) Explain the operation of SCADA.
(ii) Compare SCADA, DDC & DCS.
18. Explain with the block diagram and necessary hardware circuits the computer control with a
typical case study.
19. Describe one way that the scan rate for a single RTU could be increased beyond the scan rate for
the other RTUs.
20. (i) List the functional requirements of a distributed process control system.
(ii) Enumerate the advantages of digital computer control of processes.
21. (i) Explain the block diagram and flow chart of computer controlled systems.(10)
(ii) Mention about the protocols used in the computer controlled systems. (6)

UNIT IV - Distributed Control System

PART-A
1. Mention the hardware components of the DCS.
Local Control Unit, Data Input / Output Unit, Low Level Human Interface, High Level Human
Interface.
2. 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.
3. Mention any two advantages of DCS
More reliable Small expensive
Cost is lower than centralized system which performs the same function.
4. 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.
5. What is shared communication?
One or more communication hardware and associated software that allow the sharing of data
samong all devices in the distributed system. Shared communication facilities do not include
dedicated communication channels between specific devices.
6. 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.
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Ability to bypass 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.
7. What is the architecture parameter to be considered while selecting LCU?
Size of Controller Communication channels out of
Functionality of controller controller
Performance of controller Controller output security.
8. What is manual backup?
In this case, each LCU is designed to implement 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.
9. 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.
10. 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.
11. Compare the configuration of the controller.
Architecture
Configuration A Configuration B Configuration C
parameter
Controller size Number of function Includes functions and Equivalent to small
needed for single PID I/O DDC system
loop or motor
controller
Controller Uses both continues Uses both continues Uses both continues
functionality and logic function and logic function and logic function
Split between the
controller
Controller scalability High degree of Requires both Not scalability
scalability controller types
12. 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.
13. 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.
14. 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.
15. 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.
16. Write down any four salient advantages of DCS over centralized control systems.
Scalability and expandability
Control capability More reliable
Operator interfacing capability Small expensive
Cost is lower than centralized system, which performs the same function.
17. List the factors to be considered for types of communication in DCS.
There are many factors to take into account when choosing the best medium for particular
application, including speed and distance of data transmission, topology of the network, and target
costs.
18. Name few popular communication buses used in DCS. (May2013)
Control Bus Address Bus
Data Bus IEEE 488 BUS

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19. Give some applications of DCS. (May2014)
Distributed control systems (DCSs) are dedicated systems used to control manufacturing
processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station
power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, cement production,
steelmaking, and papermaking.
20. What are the major architectural parameters to be considered for designing a controller for
various industrial control applications? (May2014)
The major architectural parameters are: Scalability and Expandability, Control capability,
Operator interfacing capability, integration of system functions, Significance of single point failure,
Installation costs, and Maintainability.
21. Write some of the bus standards used in process control industry. (Dec2014)
HART Protocol Modbus
PROWAY (Process data high way) IEEE 488 BUS
Controller Area Network IEEE 802 Networks.
22. List any four functional blocks mostly used in commercial DCS. (May2015)
The various functional blocks used in commercial DCS are Access Control, MMI, Trending,
Alarm Handling, Logging/Archiving, Report Generation, and Automation.
23. What is DCS? Differentiate PLC and DCS. (May2015)
DCS (Distributed Control System) is a computerized control system used to control the
production line in the industry. The entire system of controllers is connected by networks for
communication and monitoring. DCS is a very broad term used in a variety of industries, to monitor
and control distributed equipment.
24. Define DCS with an example. (Dec2015)
A distributed control system (DCS) is a control system for a process or plant, wherein control
elements are distributed throughout the system. This is in contrast to non-distributed systems, which
use a single controller at a central location. In a DCS, a hierarchy of controllers is connected by
communications networks for command and monitoring.
Example scenarios where a DCS might be used include:
Chemical plants
Petrochemical (oil) and refineries
Pulp and Paper Mills
Nuclear power plants.
25. What do you mean by local control unit? (Dec2015)
Local control unit is the smallest collection of hardware in the system that can do closed loop
control. Local control unit interfaces directly to the process.
26. Compare individual, centralized, and distributive control systems. (Dec2013/May2016)
Features Individual Centralized Distributed
1. Scalability and Good - due to Poor very limited Good - due to
expandability modularity range of system size modularity
2. Control capability Limited analog and Full - digital control Full - digital control
sequential control capability capability
hardware
3.Operator interfacing Limited by panel Digital hardware Digital hardware
capability board instrumentation provides significant provides
improvement for large improvement for full
systems range of system sizes
4. Integration of Poor - due to variety All functions Functions integrated in
system functions of products performed by central a family of products
computer
27. What is the role of communication interfaces in DCS? (Dec2013/May2016)
Communication interface reduce Cost of plant wiring (1000 of wires are replaced by the few
cables or buses used to implement shared communication system). Flexibility of marking changes
increases because of it is software configuration. Less time to implement large system since the
wiring labor is nearly eliminated, Configuration error reduced. Control is more reliable due to
reduction in physical connection. So failure is easily identified.
28. Define DCS? (Dec2014/Dec2016)
DCS (Distributed Control System) is a computerized control system used to control the
production line in the industry. The entire system of controllers is connected by networks for
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EI6702 Logic and Distributed Control System Department of EIE 2017-2018
communication and monitoring. DCS is a very broad term used in a variety of industries, to monitor
and control distributed equipment.
29. Write the features of shared communication facility used in DCS. (Dec2016)
One or more levels of communication hardware and associated software that allow the sharing of
data among all devices in DCS. Shared communication facilities do not include dedicated
communication channels between hardware elements within the device.

PART-B
1. (i) Discuss Local Control Unit (LCU) and DCS.
(ii) Explain the LAN topology of DCS in detail. (May2016)
2. Describe the different types of alarms and alarm management in DCS. (May2016)
3. Describe the functions performed by every block of DCS. (Dec2016)
4. Explain the functioning of local control unit and compare any two architectures. (Dec2016)
5. Explain the importance of DCS and mention the software used in DCS. (Dec2015)
6. (i) What are all the process interfacing issues related to DCS? (8)
(ii) Mention the important communication facilities used in a process industry. (8) (Dec2015)
7. (i) Discuss Local Control Unit (LCU) of DCS. (8)
(ii) Explain the LAN topology of DCS in detail. (8) (May2015)
8. Describe different types of alarms and alarm management in DCS. (May2015)
9. (i) Mention the important of communication facilities used in a process industry. (8)
(ii) In a petroleum industry what are all the process interfacing issues related to DCS. (8)
(Dec2014)
10. (i) Explain the components used in distributed control system. (12)
(ii) Brief about local control unit used in a process industry. (4) (Dec2014)
11. (i) Discuss briefly interaction between LCU architecture and the communication devices in the
DCSs.
(ii) Describe different types of alarms and alarm management in DCS. (May2014)
12. What are several functions to be accomplished by the communication interfaces in DCS? Also
explain LCU interfaces to distributed systems with diagram (May2014)
13. Describe the hierarchy of DCS with neat diagram. (Dec2013)
14. Describe the local control unit and communication facilities used in any process industry.
(May2013)
15. (i) How to select topology and communication protocol of process control application? (8)
(ii) Explain any one popular communication protocol used in field level. (8) (Nov2012)
16. Discuss the different architectures of DCS with necessary diagrams.
17. (i) Explain the process interfacing issues in the petroleum industry.
(ii) Explain the communication facilities used in the petroleum process industry.
18. With neat diagrams explain redundant controller design configurations.
19. Explain LCU manual backup design configurations.
20. (i) List the requirements of LCU.
(ii) Compare DCS and DDC.
21. Explain the display hierarchy in DCS.
22. Illustrate the usage of distributed digital control in any one process industries with a neat
architecture.
23. Discuss the following: (i) Ethernet (ii) Control Net.
24. Explain security design issues for the local control unit.

UNIT V - Interfaces in DCS

PART-A
1. In a thermal power plant, how they are classified the control system?
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EI6702 Logic and Distributed Control System Department of EIE 2017-2018
Semi-automatic system: easy to understand and simple and economical.
Full automatic system: easy and reliable operation.
2. 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.
3. What is semi-automatic system?
All continuous modulating controls during normal on-load operation and some start up
modulating controls, such as turbine run up controls, are handled automatically by individual sub-
loop controllers, whereas most start up modulating and binary controls are executed manually.
4. What are the problems which may occur in the power plant?
Requirement Problem Solution System
Rapid load To reduce steam Predictive control
response temperature error due to Dynamic balancing
slow response of fuel loop control
Reliable plant To diagnose system Decentralizing control Totally
operation condition and to continue functions duplicating distributed
plant operation in case of main portions. digital control.
fault.
Ease operation To fully automate plant Centralizing monitoring
operation and obtain quick functions displaying fault
recovery from faults portions
5. What is fully automatic system?
Most start up modulating and binary controls are executed automatically. Significant
improvement of man machine communication with color graphic displays and voice communication.
Most plant control sub loop controllers are digital and connected to the unit computer with data busses
comprising a distributed digital control system.
6. 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.
7. What are the main processes of power station?
Combustion, water / steam, electricity generation, cooling etc.
For the sub processes are feed water, mills, FD fans etc.
8. 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.
9. Mention the requirement of operator interface.
Process monitoring
Process control
Process record keeping
10. Mention the buses of the power plant DCS
Group bus Peripheral bus
Plant bus Back up bus
11. Mention the hardwares of the power plant DCS
Field stations Unit level control station
Sub group control stations Manual control station.
Group control stations Diagnostic station.
12. What is data logger?
A provision is made for assigning of a number of printers at the unit level for logging functions. It
is also possible to select any printer for any type of log that can be initiated on demand times.
13. What are the basic models built for blast furnace?
Statistical models Material and energy balance
Thermo dynamical models model.
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14. In the steel process, which are all the things to be controlled?
Time, for economical reasons, time element being critical.
Temperature , with in the narrow limits
Raw material mix- steel, sulphur, aluminium, manganese and dissolved gases.
15. What are the main and sub process involved in iron and steel process?
Ore treatment plant Electric arc furnace
Blast furnace Continuous casing plant
Basic oxygen furnace Rolling mill
Direct reduction plant
16. What are the three modes of DCS?
Computer automatic Manual
Automatic and remote
17. Mention the applications of DCS in rolling mills
Control process in multi-loop configuration Interconnection of the number of processes
High speed control Graphical display of fast changing analog
Fully digital drive control system with variables
microprocessor control
18. What are role of plant operators in plant?
These people are responsible for monitoring, supervising and running the process through the
control system during startup, operation and shutdown conditions.
19. What are the responsibilities of instrumentation engineer in plant?
Instrumentation and control system engineers are responsible for settling up the control system
initially and adjusting and maintaining it from time to time afterwards.
20. Briefly explain process diagnostics.
Monitoring and controlling the process under normal operating conditions are relatively simple
functions compared to operation under abnormal or hazardous conditions caused by failures in
plant equipment or in the instrumentation and control system. The operator interface system must
provide enough information during these unusual conditions to allow the operator to identify the
equipment causing the problem, take measures to correct it and move the process back to its
normal operating state.
21. What is the function of engineering interface?
System configuration System documentation
Operator configuration System failure diagnosis
22. List the some specific Process Record keeping requirements.
Recording of short-term trending information.
Manual input of process data
Recording of alarms
Periodic records of process variable information
Long-term storage and retrieval of information
Recording of operator control actions
23. Mention the function of operator interface system.
The basic function of the operator interface system is to allow the operator to observe and monitor
the current state of the process. This function includes the current values of all process variables
of interest in the system must be available for the operator to view at any time. Each process
variable is identified by a tag name.
24. What are the common input and output devices used for interfacing with computers?
* Manual backup devices and redundant control devices
* Fuses and signal conditioning hardware such as filters
* External supplies that provide power to sensors and field contacts
* Switches and jumpers used to select I/O options.
25. What three types of data received from plant processes are collected and stored by the
DCS?
Digital data, Analog data and Computed data.

26. State the main functions of computers in DCS. (May2013)

Process monitoring Trend in time
Alarming Process control
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Process diagnostics Process record keeping
27. Justify the need for operator interfaces in DCS. (Dec2013)
The operator interfaces in typical Distributed Control System are used to describe DCS
capabilities, plant and processes are accessed and controlled from the DCS controllers. Operator
interface are used to interpret control system diagrams into plant control loops, used to describe basic
Unit loading and control features.
28. Mention the significance of computers in modern control systems. (Dec2013)
Computer utilizes the same measurement information about the process used by human operators.
Automatic control strategy is composed of a sequence of control rules, describing the relationship
between process conditions and control actions.
29. State the need of HMI. (May2014)
A Human-Machine Interface or HMI is the apparatus which presents process data to a
human operator, and through this, the human operator monitors and controls the process. A
supervisory (computer) system, gathering (acquiring) data on the process and sending
commands (control) to the process.
30. Write the function of engineering interface hardware. (May2014)
Engineering interface hardware must perform the following functions:
System configuration
Operator interface configuration
System documentation
System failure diagnostics
31. Mention the protocols to be used for communication between a PC Drive/Operator Panels.
(Dec2014)
The rules or conventions that govern the transmission of data in the system are usually referred to
as protocols.
BISYNC(Binary synchronous communications Protocols)
DDCMP(Digital data communications message protocols)
SDLC(Synchronous data link control)
HDLC(High-level data link control)
ADCCP(Advanced data communications control protocols)
32. What flexibility does the control and monitoring systems provide for defining trend data?
(May2015)
CRT controller sub-module interfaces main processor to Visual Display Unit, which is used to
show the status of process by displaying transducers values, present set points entered through manual
entry sub-module, historical trend of various parameters, mimic diagram of process, alarm status etc.
All the above display tasks are provided in the main processor through software. LED/LCD control
sub-module interfaces array of LED/LCD to main processor. Alarm annunciator controller sub-
module generates ON-OFF signal for each type of alarm.
33. Write the communication system requirements in DCS (May2015)
Minimize delay and maximize security transmission
Transmission of PV, CV and Alarm status information from LCU to HLHI,LLHI.
Communication of special commands, operating modes, CV from the HLHI to LCU for the
purpose of supervisory control.
Down loading of control system configuration, tuning parameters and user programs from
HLHI to LCU
Transmission of information from data input/output unit to high level computing devices for
the purpose of data acquisition.
Transfer of large block of data (data base)/programes from one high level computing devices
to another high level computing devices or low level computing devices.
Synchronization of real time among all of the elements in the DCS

34. Mention some of the protocols used in DCS system (Dec2015)

HART Protocol Modbus
PROWAY (Process data high way) IEEE 488 BUS
Controller Area Network IEEE 802 Networks
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Device Net Profibus.
35. Mention the display hierarchy used in DCS system (Dec2015)
Plant display, Graphic display.
Area display. Trend display.
Group display. Tabular display.
Loop display.
36. Mention the features provided in operator interfaces. (May2013/May2016)
The operator interface in a distributed control system must allow the operator to perform tasks in
the following traditional areas of responsibility: Process monitoring, process control, process
diagnostics, and process record keeping.
37. State the main functions of computers in DCS. (May2016)
Main functions of the computers are data acquisition, data logging, and computational functions.
38. Compare operator interface with engineering interfaces. (Dec2014/Dec2016)
Operator Interfaces: The operator interface in a distributed control system must allow the
operator to perform tasks in the following traditional areas of responsibility: Process monitoring,
process control, process diagnostics, and process record keeping.
Engineering Interfaces: Engineering interface hardware must perform the following functions:
System configuration, Operator interface configuration, System documentation, and System failure
diagnostics.
39. Write the important features incorporated in high level engineering interface. (Dec2016)
The high-level engineering interface allows a user to reap the full benefits of the
flexibility and control capabilities of a DCS while minimizing the system engineering costs
associated with such a system. Although more expensive than the low-level version, this
device is extremely cost effective when used in conjunction with medium to large scale
systems because of the significant engineering cost savings it can provide.
The HLEI is implemented in the form of a CRT based console or VDU, similar to the
high level operator interface unit. Flexibility in accommodating hardwares, like special
keyboards or printers. Same elements of operator interface used for engineering interface.
Like the VDU, the engineering console can interact with any other elements in DCS through
the shared communication facility.

PART-B
1. (i) Discuss the features of high level operator interfaces in detail.
(ii) Explain the hierarcy of operator display used in DCS. (May2016)
2. List the various engineering interfaces used in DCS. With neat diagram explain the low and high
level engineering interfaces. Differentiate between them. (May2016)
3. Describe any one typical architecture used for operator interface at low and high level.
(Dec2016)
4. Explain the functions and features incorporated in the engineering interface at low and high level
apllication with an suitable example. (Dec2016)
5. (i) Compare the features present in low level and high level operator interfaces with examples.(6)
(ii) Explain the operator displays used in any of the process industry. (10) (Dec2015)
6. (i) Explain any one architecture of high level engineering interface. (8)
(ii) Explain the uses and need for interfacing general purpose PC with DCS. (8) (Dec2015)
7. What is the difference between redundancy and Fault tolerance? Explain the redundancy concept
available in controller level. (May2015)
8. Explain the structure of typical display hierarchy of industrial control systems with suitable
diagram. (May2015)
9. (i) Discuss the features of high level operator interfaces in detail. (6)
(ii) Explain the operator displays used in any of the process industry. (10) (Dec2014)
10. (i) Describe with an example low level and high-level engineering interfaces. (6)
(ii) Explain the role of general-purpose computers in DCS. (10) (Dec2014)
11. Illustrate the structure of typical display hierarchy industrial control system with suitable
diagram. (May2014)
12. Explain the functional requirements of operator interfaces in monitoring process control and
process record keeping. (May2014)
13. Explain the different displays followed in industrial control systems. (Dec2013)
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14. Discuss the low level and high level operator interfaces in DCS. (Dec2013)
15. List the various engineering interfaces used in DCS. With neat diagram, explain the low and high
level engineering interfaces. Differentiate between them. (May2013)
16. (i) Compare low level and high level operator interfaces. (6)
(ii) Explain the operator displays used in any of process industry. (10)
17. Explain the automation of power plant using DCS?
18. Describe how DCS can be used for controlling Iron and steel plant .
19. Describe how DCS can be used for controlling Chemical Plants.
20. Describe how DCS can be used for controlling Cement Plants.
21. Describe how DCS can be used for controlling Pulp and Paper Plants.
22. Explain the low level Engineering interface with diagram.
23. Explain the high level Engineering interface with diagram.
24. (i) Mention the advantages and disadvantages of low level and high level operator interfaces.(6)
(ii) Explain the importance of operator displays used in a process industry. (10)
25. (i) Evaluate low level and high level engineering interfaces. (6)
(ii) Mention the role of purpose computers in DCS. (10)

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