Advanced PLC Programming, Level 4.

Course Title: Advanced PLC Programming

Course Description:

The PLC Programming: Level 4 course is designed to provide participants with advanced knowledge and skills in programming and troubleshooting Programmable Logic Controllers (PLCs).

This course is targeted towards individuals who already have a strong foundation in PLC programming and wish to further enhance their capabilities.

Participants will delve into advanced programming concepts, explore complex control strategies, develop proficiency in troubleshooting techniques, and gain hands-on experience with industry-standard PLC systems.

Course Outline:

Module 1: Advanced PLC Programming Concepts

  • Review of basic PLC programming concepts
  • Introduction to advanced programming techniques
  • Advanced ladder logic programming
  • Function block diagram (FBD) programming

Module 2: Complex Control Strategies

  • Sequential control using timers and counters
  • Data manipulation and arithmetic operations
  • Advanced control instructions: shift registers, compare and jump instructions
  • Math instructions and floating-point arithmetic

Module 3: Analog I/O and PID Control

  • Analog input and output modules
  • Scaling and calibration of analog signals
  • Introduction to PID control
  • Configuration and tuning of PID controllers

Module 4: HMI Integration and SCADA Systems

  • Human Machine Interface (HMI) design and development
  • Integration of HMI with PLC systems
  • Data exchange between PLC and HMI
  • Introduction to Supervisory Control and Data Acquisition (SCADA) systems

Module 5: Networked PLC Systems

  • Introduction to industrial networks (Ethernet, Profibus, etc.)
  • PLC network configuration and communication protocols
  • Remote I/O and distributed control systems
  • Network troubleshooting and diagnostics

Module 6: Advanced Troubleshooting Techniques

  • Understanding and analyzing PLC system faults
  • Advanced troubleshooting methodologies
  • PLC program debugging and online monitoring
  • Use of diagnostic tools and software

Module 7: Safety Systems and Emergency Shutdowns

  • Introduction to safety-related control systems
  • Safety PLCs and Safety Instrumented Systems (SIS)
  • Safety concepts: fault tolerance, fail-safe, and fail-operational
  • Emergency shutdown (ESD) systems and interlocks

Module 8: PLC System Maintenance and Upgrades

  • Preventive maintenance strategies for PLC systems
  • Component replacement and firmware upgrades
  • System backup and restore procedures
  • Documentation and version control practices

Module 9: Project Design and Implementation

  • Understanding project requirements and specifications
  • PLC system design and configuration
  • Integration of sensors, actuators, and peripheral devices
  • Hands-on project implementation and testing

Module 10: Industry Standards and Best Practices

  • Compliance with relevant industry standards (IEC 61131, ISO 9001, etc.)
  • Good programming practices and code organisation
  • Documentation and project management guidelines
  • Continuous improvement and adaptation to evolving technologies

Module 11: Case Studies and Practical Exercises

  • Analysis of real-world PLC programming applications
  • Hands-on exercises for advanced programming techniques
  • Simulation of complex control strategies
  • Troubleshooting scenarios and practical problem-solving exercises

Module 12: Assessment and Evaluation

  • Practical assessments to evaluate participants’ programming and troubleshooting skills
  • Written assessments to test theoretical knowledge
  • Evaluation of participants’ ability to apply concepts to practical scenarios
  • Feedback and recommendations for improvement

Note: The course outline provided above is a general framework and can be customized and expanded upon based on specific requirements, industry focus, and available time for the course.