Engineering Encyclopedia

Saudi Aramco DeskTop Standards

PROJECT MANAGEMENT OF A PLC SYSTEM

Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.

Chapter : Process Instrumentation For additional information on this subject, contact

File Reference: PCI-113.07 PEDD Coordinator on 874-6556
Engineering Encyclopedia Introduction to Programmable Logic Controllers

Project Management of a PLC System

Section Page

PROJECT OBJECTIVES ............................................................................................... 3

OPERATIONAL VALIDATION REQUIREMENTS.......................................................... 4
Engineering Design Review ...................................................................................... 4
System Design .................................................................................................... 4
Hardware design ................................................................................................. 5
Piping and Instrumentation Diagram (P&ID)........................................................ 5
Software Design Review........................................................................................... 6
Functional Program Requirements ...................................................................... 6
Written Description .............................................................................................. 6
Logic Diagrams.................................................................................................... 7
Cause & Effect Diagrams .................................................................................... 7
I/O Listing ............................................................................................................ 8
Vendor Document Review ........................................................................................ 9
Drawing Review.................................................................................................. 9
Software Review................................................................................................ 10
PLC SYSTEM FACTORY TESTING REQUIREMENTS .............................................. 11
Factory Acceptance Test (FAT) procedures ........................................................... 11
Saudi Aramco FAT Procedures ......................................................................... 13
Functional Testing................................................................................................... 13
Hardware Simulation ......................................................................................... 13
Program Verification (Debugging) ..................................................................... 15
Radio Frequency Interference (RFI) Testing........................................................... 16
PLC SYSTEM COMMISSIONING CHECKS AND TESTS........................................... 19
Physical Checks...................................................................................................... 19
Electrical Testing..................................................................................................... 20
I/O Wiring To All Field Devices .......................................................................... 20
Field Interconnecting Wiring .............................................................................. 22
Manual Program Testing......................................................................................... 22
Stroke Valves .................................................................................................... 23
Bump Motors And Check For Proper Rotation .................................................. 24
System Operation Under Manual Control.......................................................... 24
Automatic Program Testing .................................................................................... 24
Automatic System Operation ............................................................................. 25
Turnover System ............................................................................................... 26
GLOSSARY ................................................................................................................. 27
ADDENDUM: FACTORY ACCEPTANCE TEST (FAT) PROCEDURE FOR A
PLC SIMULATOR ........................................................................................................ 29

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LIST OF FIGURES

Figure 1. System Drawing List ...................................................................................... 9

Figure 2. System Boundaries for Penetration of Electrical Noise ................................ 17

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PROJECT OBJECTIVES

The project engineer is assigned the responsibility to manage a

technical project or program in a manner that will result in
meeting the project objectives.

The three basic objectives for the project engineer are:

1. Deliver a product that meets the requirements of the

specifications.

2. Deliver a product that meets the requirements of the

contract delivery schedule.

3. Achieve the organization’s cost objective for the contract.

While items 2 and 3 are of equal importance to a project, this

module is intended to concentrate on producing a product that
meets the technical aspects of the project.

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OPERATIONAL VALIDATION REQUIREMENTS

Validation of the operational requirements of a PLC system is
required to ensure that the PLC vendor may proceed with detail
design, manufacturing, programming, and other efforts required
to meet the operational requirements.

The tasks included in the validation process include both an

engineering design review and a vendor document review.

Engineering Design Review

Most projects involve a contract between two parties.

Engineering design with its specifications form an integral part
of the contract. Before a contract is released for construction,
the engineering design must be complete and correct.

The engineering design review, one of the many tasks for a

project, ensures the completeness of the system design. The
activities that take place during the engineering review include
the following:

• System Design
• Hardware Design
• Piping and Instrumentation Diagrams (P&IDs)

System Design
The system design formulates overall PLC system requirements
for the PLC project. The project must start with a description of
the process to be controlled and the process operational
requirements. The description should provide the following:

• A detailed statement of the control tasks.

• A description of the design task philosophy to be used to

achieve the control tasks. The design philosophy should
define the functions of the major hardware and software
components of the system.

• The objectives that must be achieved. The objectives also

allow the success of the control implementation to be
measured.

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The design specifications provide the engineering design

information so that the contractor is not required to create an
original design. The contractor must have the ability to interpret
and translate the information on the design documents and
drawings into the hardware.

Handout #4 contains a Description of Operation for the

simulator used in this course. The system description, coupled
with the P&ID, and the system drawings, provided the basis for
the PLC hardware and the PLC programming.

Hardware design
Hardware design refers to the physical parts of the PLC system
such as the CPU, I/O modules, local and remote chassis, power
supplies, cables, and the control panel with its associated
components.

System drawing #422-I/O, Sheet 1 provides the bill of material

for the PLC required for the simulator. System drawings #422-
CP define the control enclosure and the components associated
with the control enclosure. These drawings define the required
hardware and provide the information required for a vendor to
provide a quote for supplying the system equipment.

Piping and
Instrumentation
Diagram (P&ID)
The P&I diagram is an engineering document used to define the
process to be controlled and to designate instruments and
instrumentation systems to be used for measurement and
control of the system.

The P&ID is one of the prime documents required for a PLC

system. From the P&ID the system designer will determine the
amount and different types of I/O signals required as inputs and
outputs for the PLC. This information is used to determine the
size of PLC required for control of the system. Drawing
422-P&I, Sheet 03 represents the P&ID for the simulator PLC
system used in this course.

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The process shown in drawing #422-P&I, Sheet 03 is designed

to load fixed amounts of products A and B into Batch Mixing
Tank T-101. When all the products are loaded into the mixing
tank the combination is mixed for a fixed time period. At the
end of the mixing time, the mixing is stopped and the mixed
product is transferred to storage tank T-214. The transfer
controls are not shown on this portion of the P&ID.
Components are included to allow the operator to wash the
mixing tank when all of the product has been transferred to the
storage tank.
Software Design Review
The software design review is used to verify the functional
program requirements and written description for the PLC
system.

Functional
Program
Requirements
The functional description contains the operational requirements
for the control system, the necessary interlocks, and the alarms.
The functional program requirements are the basis for the PLC
program.

The functional requirements for the PLC simulator used in this

course are defined in the Addendum.

Written
Description
The written description of the process defines the control tasks
and the design philosophy for the system. The following
description is an example of the requirements for the PLC
simulator.

Control tasks - The Product 1 Blending System is used to

control the mixing of products A and B in a 1:1 ratio to produce
a product with the desired chemical consistency. Products A
and B are metered into a mix tank and stirred for a fixed amount
of time to produce the desired consistency. The mixed product
is transferred to a storage tank for future use.

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Wash cycles are part of the operation. The Product 1 Mix Tank
is flushed with water (Wash 1 cycle) prior to operating the
blending process. A wash 2 cycle is used prior to the mixing a
batch with different consistency.

Design philosophy - The Product 1 Blending Process is

designed for automatic operation using an Allen-Bradley PLC-5
programmable logic control system. Manual operation of the
valves and pumps is intended for testing only. The exception to
this is flow valves FV-101 and FV-102. After products A and B
are mixed they are tested for proper chemical consistency. If
the product is out of specification the operator will manually add
additional amounts of ingredient A or ingredient B.

A mimic panel is included with the system to allow the operator

to monitor the various sequences in the batch operation.
Included with the mimic panel are six alarm lights and Test,
Acknowledge, and Reset push buttons.

The front panel of the control panel is to contain the operating

controls and level indicators for tanks TK-101 and TK-214.

Logic Diagrams
A binary logic diagram is an engineering diagram that
represents the functional operation of a given device or system.
The logic diagram is not meant to convey the specific type of
hardware used to execute a function, but merely to define the
functions that must be performed in order to obtain the desired
result. Therefore, while the actual hardware used for the control
system may be electromechanical or solid state components,
the logic concept or sequence of operation is identical.

Cause & Effect

Diagrams
A cause and effect diagram is a two dimensional matrix that
defines, either on a time or event basis, the relationship
between a device in the control system and the time or event
operation of an output device. These charts are commonly
used in documenting shutdown safety logic, control interlocks,
and sequential control functions.

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PLC software incorporates a version of the cause and effect

diagram to define the relationship between PLC output signals
and control steps that are time or event driven.

I/O Listing
Inputs and outputs refer to the signals coming into and going
out of the PLC, such as valve position, mode selection, and tank
level. These signals originate with limit switches, selector
switches, and level switches.

The first step in documenting the PLC I/O requirements is to

compile a list of all the signals monitored and controlled by the
PLC. The information associated with this list is the tag
number, PLC address, and a description of the signal. The
database report generated with the Topdoc software can be
used as an I/O list.

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Vendor Document Review

Vendor document review is an important review as it allows the
project engineer to verify the completeness of the documents
and their engineering content. The document review includes
both the engineering drawings and the software.
Drawing Review
Drawing review is required prior to any purchase of materials
and construction in order to check for component selection,
system design, and technical correctness. System drawing for
the simulator in this course include all the drawings listed on the
drawing list shown in Figure 1.

ITEM DWG. SHEET DESCRIPTION

NO.
1 422-P&I 03 P&ID Product 1 Blending Process
2 422-LD1 01 Basic Logic Diagram FV101 Manual/Auto Open/Close Logic
3 422-L 01 Symbols Legend
4 422-I/O 01 Simulator PLC Logic Module Assignment
5 422-I/O 02 I/O Arrangement Input Signals Rack 0, Groups 1 and 2
6 422-I/O 03 I/O Arrangement Input Signals Rack 0, Groups 3 and 4
7 422-I/O 04 I/O Arrangement Output and Input Signals, Rack 0 Groups 5 and 6
8 422-I/O 05 I/O Arrangement Future I/O Rack 0 Group 7
9 422-I/O 05 I/O Arrangement Output Signals Rack 1 Groups 1 and 2
10 422-I/O 07 I/O Arrangement Output Signals Rack 1 Groups 3 and 4
11 422-I/O 08 I/O Arrangement Output Signals Rack 1 Groups 5 and 6
12 422-I/O 09 I/O Arrangement Output/Input Signals Rack 1 Group 7/Rack 2 Group 0
13 422-I/O 10 I/O Arrangement Future I/O Rack 2 Groups 1 and 2
14 422-I/O 11 I/O Arrangement Future I/O Rack 2 Group 3
15 422-EWS 01 Electrical Wiring Schematic Power Distribution
16 422-EWS 02 Electrical Wiring Schematic Power Distribution
17 422-EWS 03 Electrical Wiring Schematic Power Distribution
18 422-CP 01 Training Simulator Plans and Elevation
19 422-CP 02 Training Panel Subpanel 1 Layout
20 422-CP 03 Training Simulator Subpanel 2 Layout
21 422-CP 04 Training Simulator Cutout Details
22 422-CP 05 Training Simulator Mimic Panel Arrangement Front View
23 422-CP 06 Training Simulator Mimic Panel Arrangement Rear View
24 422-CP 07 Training Simulator Front Door Layout Front View
25 422-CP 08 Training Simulator Front Panel Layout Rear View

Figure 1. System Drawing List

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Software Review
The software review, at this stage of the project, is used to
confirm that the developed software program conforms to the
buyer specifications for structure and format. A functional check
of the program is not performed at this time as the functionality
of the program will be confirmed at the Factory Acceptance Test
(FAT).

The requirements for PLC program structure is defined in

34-SAMSS-830, Section 8.5 PLC program development is to
include the following requirements.

1. The PLC program is to be designed to promote ease of

understanding by both the operations and maintenance
personnel. Complex rungs and instructions are to be
avoided.

2. Networks and rungs are to be arranged so that all logic for

a specific piece of equipment (or function) are grouped
together.

3. Input/output (I/O) and internal addresses are to be

documented with tag names and element descriptors.
Rung comments are to be used to explain the functions of
a rung or groups of rungs.

PLC reports, such as data base and data table, are not required
at this phase of the project. These reports are submitted at the
conclusion of the FAT.

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PLC SYSTEM FACTORY TESTING REQUIREMENTS

Factory Acceptance Test (FAT) procedures

A FAT for a PLC system consists of an inventory of equipment,

visual inspection of the equipment, and functional testing of the
total hardware system. Factory acceptance testing may be
broken into two separate activities:

• Acceptance of the PLC system hardware.

• Acceptance of the functional testing of the system

hardware and the PLC control program.

The factory acceptance test usually occurs at the vendor facility

where accepting the hardware and the functional testing of the
hardware and the PLC software control program can be
accomplished at the vendors’ staging facility. This execution is
dependent on how the configuration duties for the project have
been planned and the timing works out between completion and
hardware manufacturing. If the hardware vendor is responsible
for the PLC software control program, both the software control
program and the hardware may be accepted by the buyer at a
single test. If the PLC software control program is done
elsewhere, it may be necessary to divide the hardware test from
the software control program test.

Regardless of how the acceptance tests are executed, the

following are some of the items to check for with respect to the
PLC system hardware:

1. Inventory all hardware modules as listed on the purchase

order. Also check all cables, fuses, and all of the
miscellaneous items that are easy to forget, but can delay
staging or startup activities for days if they are missing.

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2. Verify the operation of each hardware module, and witness

proper communications between modules.
Communications are critical and should be carefully
reviewed and checked for complete functionality. This is
very important when connecting hardware modules
together that are manufactured by different vendors or
communications software that was specifically written for
this project. Be sure to witness proper communications
before acceptance of the digital system hardware. Do not
approve shipment of any hardware until full functionality of
the system has been proven. It is very difficult to finish
systems designs in the field or the staging facility, a
procedure that should be avoided at all costs.

3. Test all of the inputs and outputs supplied with the system.
Each type of I/O should be tested using proper simulation
gear, including switches, loads (lights for example), signal
generators (4-20 mA, 1-5 Vdc, frequency), and signal
meters. Usually, 25 percent of the I/O, randomly selected,
is sufficient for factory acceptance. The vendor should
have checked 100 percent when building the system.

4. Review the power distribution design of the system for

proper grounding techniques and circuit protection. This
should have been checked when approving the vendor
drawings but should be reviewed at the acceptance test.

5. Check the equipment for special items that are required for
installation or staging, such as mounting brackets, power
requirements, ground lugs, cable entry access, and similar
details.

With respect to application program acceptance, some of the

items to consider are as follows:

1. Check the control strategies for proper operation. These

include shutdown logic, advanced calculations, batch
sequencing, and control cascades.

2. Account for the configuration of all of the I/O and the

associated tag descriptions, ranges, alarm setpoints, and
similar point data.

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3. Check all code development printouts for proper

documentation requirements. Operability of much of the
custom code and control strategy implementations can be
fully proven only in the field during startup and operation.

In summary, develop a checklist that incorporates all of the

details to be covered during the acceptance test period. The
checklist will make it easier to execute a structured analysis of
the system and assure that all criteria have been addressed.

Saudi Aramco FAT

Procedures
Section 11 of Saudi Aramco 34-SAMSS-830 explains the
responsibility for the functional testing, both hardware and
software, and the supplying of all test equipment.

Functional Testing

The objective of the functional test is to exercise all the

equipment, including the PLC equipment, and to test and debug
the PLC program. Functional testing done prior to installation of
the system in the plant facility is extremely important. Problems
that are found in the factory test save time rather than
debugging the problems in the plant. The functional testing
includes both hardware testing and testing of the PLC program.

Hardware
Simulation
It is not practical to use actual field devices such as valves and
motors for the factory acceptance test. Therefore, input and
output devices are simulated using switches and push buttons
as input devices and lights and relays as output devices. The
testing procedures described below assume simulation of the
input and output devices and monitoring of the desired output
responses. While this is not the same as that found in actual
plant operation, it achieves testing of the hardware devices and
the PLC hardware.

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PLC Operation - All the PLC hardware must be exercised to

verify the functionality of the hardware and to eliminate any
malfunctions. The procedure is basically as follows:

1. Turn on the PLC system power supply modules and verify

that the status indicator on the power supply module and
the PLC are ON. This verifies that power supplies and the
PLC, as far as the power is concerned, are functioning.

2. With the system power supply turned ON, verify that the
active status indicator on the input modules is ON.

3. The PLC, when first installed, does not contain a program.

When first powered, the memory in the PLC is faulted and
the PLC fault light will be ON. Connect the programming
terminal to the PLC and download a test program to the
PLC. During the download process the PLC memory will
be cleared and the program loaded into the PLC memory.
After the download, the PLC fault light should be OFF.

4. Place the PLC key switch in the RUN mode. When the
PLC is placed in the RUN mode, the active light on the
output modules should be ON.

I/O Verification is required to ensure that all the input modules

are functioning and input signals are read into the PLC and
output modules are functioning and can control output devices
connected to the output modules.

1. To test the input system, connect switch or push buttons to

the input points. For a large system is may be necessary
to connect switches to only one section and then move the
switches to another section after testing the first section.

Close each switch and observe that the corresponding

status light on the input module comes ON. In addition,
monitor the PLC input status table with the programming
terminal and observe that the status bit for each input
changes from a 0 to a 1 or from a 1 to a 0. This can only
be observed if the PLC is in the RUN or TEST modes.
Verifying the changes in the PLC data table is absolute
proof that the input system is working and that the signal
status is being read in the PLC data table.

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2. Connect lights to the outputs that are to be tested.

3. The test program loaded in the PLC in a prior step should

contain a few rungs of a program that can be used to
exercise the PLC outputs. Use an input to control an
output and enabled the input. The corresponding output
should be enable and the device connected to the output
should be ON. Verification that the output devices respond
to changes in the input signal verifies that the output
modules are functioning and that the CPU is functioning.

Program
Verification
(Debugging)
After all the input and output system and devices are verified
the program testing can proceed. The PLC program is
developed from a system description, logic drawings, and, if
available, cause and effect diagrams.

The program verification will include the following:

1. Review all of the system-specific configuration tasks for

completeness. These tasks will be unique to each digital
system type and must be obtained from the digital system
standard documentation. They might include establishing
groups, units, areas, hardware personalities, color
schemes, annunciation details, and the like.

2. Use the I/O wiring diagrams to verify the system input and
output signals in accordance with the program printout.

3. Inspect the hard copy of the program for entry errors that
may have occurred during program entry.

4. Check each rung for correct logic operation and modify

the logic as necessary. Ensure that the program
documentation for each rung is complete.

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System Operation With Simulated I/Os - The use of switches

as input devices and lights as output devices will verify the
operation of the input and output system and the PLC logic.
However, it will not test the system under dynamic conditions.
In order to achieve results that are close to actual plant
operating conditions devices that can provide dynamic feedback
to the PLC should be used where appropriate. This extends the
testing period and adds additional cost to the testing
procedures, but it eliminates unexpected timing problems and
oversights in the system logic.

Dynamic simulation includes the use of relays for motor starters

and the use of the relay contacts as input status signals, actual
selector switch devices as inputs, and simulation programs to
provide output responses for analog signals.

The simulator program uses motors and limit switches to

simulate motor operated valves with their open and closed limit
switches and actual motor starters with auxiliary contacts to
provide the operational characteristics of pumps and agitator
motor.

Radio Frequency Interference (RFI) Testing

Electrical noise is an unwanted voltage or current, or both, that

appears in an electrical system. Depending on the
characteristics of the system, electrical noise may be harmful to
the proper functioning of the system. It may force the system to
malfunction. It may even lead to damage and destruction.

The electromagnetic compatibility (EMC) of an electrical system

is its ability to perform its specified functions in the presence of
electrical noise generated either internally or externally by other
systems. In other words, the goal of electromagnetic
compatibility is to minimize the influence of electrical noise.

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Electrical noise can reach the system through four different

paths, as shown in Figure 2. The four different paths are:

• Power feed lines

• Input signal lines

• Output signal lines

• Radiation

Radiation

Input Lines Output Lines

Electrical
System

Power Feed
Lines

Figure 2. System Boundaries for Penetration

of Electrical Noise

The susceptibility level of the system will be different for the four
paths of entry of the electrical noise. Furthermore, even for the
same path of entry, the susceptibility will depend upon the type
of electrical noise. For instance, for the first three entry paths,
the susceptibility will be different for common-mode noise
from that for normal-mode noise. For radiated noise the
susceptibility may depend upon the type of energy wave;
electric, magnetic, or electromagnetic.

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The susceptibility of electrical equipment to radiated noise may

be even more critical than its conducted susceptibility. Radiated
susceptibility tests are generally performed by placing the test
object very near the radiating antenna (at 1 meter) in a shielded
measuring room.

The susceptibility to the radiated electric field is generally

measured in the frequency range of 14 kHz to 1 GHz.

In testing a control system, the measuring room is the inside of

the control panel and the radiation source is a hand-held radio
transceiver (walkie-talkie), operating at 5 watts, with a frequency
range of 60 MHz to 470 MHz. The antenna is part of the
transceiver.

When keyed, the transceiver will emit 5 watts of RF energy.

The control system must withstand this emission without any
malfunction.

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PLC SYSTEM COMMISSIONING CHECKS AND TESTS

The final phase of the PLC project is the installation and
commissioning of the system. The FAT insured that the
program and the hardware conform to the design specifications.
The next step is to ship the equipment to the plant site, install
the equipment, including all the field devices and perform the
steps for commissioning the system. The steps to commission
the system include the following:

• Physical checks
• Electrical testing
• Manual program testing
• Automatic program testing

Physical Checks

Prior to applying power to the system physical inspections of the

hardware components and interconnections must be conducted.
These inspections will require time; however, this invested time
will insure a reduced total startup time, especially for large
systems with many I/O devices. The following checklist can be
used for pre-startup procedures:

• Visually inspect to insure that all PLC hardware

components are present. Verify correct model numbers for
each component.

• Inspect all CPU and I/O modules to insure that they are
installed in the correct slot locations and are placed
securely in position.

• Verify that the incoming power is wired correctly to the

power supply and that the system power is properly routed
and connected to each I/O rack.

• Verify that each I/O communication cable that links the

processor and each I/O rack is correct, according to the
I/O rack address assignment.

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• Verify that all I/O wiring connections at the interface

terminal blocks in the control cabinet are in place and are
securely terminated. This check involves using the wiring
diagrams and terminal block drawings to verify that a wire
is terminated at each point as specified by the assignment
document.

• Verify that all field interconnect wiring is in place and

properly terminated.

• Verify that all field devices are installed.

Electrical Testing

Upon completion of the physical checks electrical testing of all

input and output wiring is performed to insure that the system is
wired in accordance with the system drawings. This testing
included testing of I/O wiring to all field devices and the field
interconnecting wiring.

I/O Wiring To All

Field Devices
The checks for all field wiring includes static checking of the
input and the output wiring.

The static input wiring check is performed with power applied to

the controller and input devices. When performed, it will verify
that each input device is connected to the correct input terminal
and that the input module or point is functioning properly. Since
these tests are performed first, they will also verify that the
processor and the programming device are in good working
condition. Proper input wiring can be verified using the following
procedures:

1. Place the controller in a mode that will inhibit the PLC from
any automatic operation. This mode will vary depending
on the PLC model, but for the PLC-5 the mode is TEST or
PROGRAM.

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2, Apply power to the system and auxiliary power supplies

and input devices. Verify that all system diagnostic
indicators on the CPU, Remote I/O communication
module, power supplies, and I/O modules are indicating
proper operation. The indicators are: AC OK, DC OK,
Processor OK, Memory OK, and I/O Communication OK.
3. Verify that the emergency stop circuit will de-energize
power to the I/O devices.
4. Manually activate each input device and observe the
corresponding LED status indicator on the input module. If
properly wired, the indicator will turn ON when the field
device is activated. If an indicator other than the expected
one turns ON when the input device is activated, then it is
possible that the wiring is to the wrong input terminal. If no
indicator turns ON, then a fault possibly exists in either the
input device, field wiring, or the input module.
NOTE: Precaution should be taken when activating input
devices that are connected in series with loads that are external
to the PLC since these could cause injury or damage.

The static output wiring check is performed with power applied

to the controller and output devices. A safe practice is to first
locally disconnect all output devices that involve mechanical
motion (e.g., motors and solenoids). When performed, the
static output wiring check will verify that each output device is
connected to the correct terminal address and that the device
and output module are functioning properly. The output wiring
can be verified using the following procedures:

1. Locally disconnect all output devices that will cause

mechanical motion.

2. Apply power to the controller and to the input/output

devices. If power to the outputs can be removed by an
emergency stop, verify that the circuit does remove power
when activated.

3. Static checkout of the outputs is performed one at a time. If

the device is a motor or other output that has been locally
disconnected, re-apply power to that device only, prior to
checking. The output operation inspection can be
performed using one of the following methods:

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3.1 The PLC-5 has forcing function capabilities so that each

output can be turned ON or OFF with the use of the
programming device by forcing the output ON or OFF. If
properly wired, the corresponding LED indicator will turn
ON and the device will energize. If an indicator other than
the one expected turns ON when the terminal address is
forced, it is possible that the wiring is to the wrong output
terminal. Inadvertent machine operation is avoided since
rotating and other motion producing outputs are
disconnected. If no indicator turns ON, a fault possibly
exists in either the output device, field wiring, or the output
module.

3.2 An alternative to using the PLC force function involves

programming a test program rung that can be used
repeatedly for testing each output. Program a single rung
with a single normally-open instruction (a conveniently
located push-button) controlling the output. To test the
output, the CPU is placed in either the RUN mode. With
the controller in the RUN mode, the test is performed by
depressing the pushbutton. Observe the output device
and LED indicator, as described in the previous procedure.

Upon completion of the static output testing, all wires that were
disconnected are to be connected.

Field
Interconnecting
Wiring
Field interconnecting wiring involves the wiring between the
marshaling cabinets, the PLC I/O and the field devices. The
field wiring is effectively tested during the static output wire test.
If a PLC output is enabled and the corresponding controlled
device becomes active, the interconnecting wire is validated.

Manual Program Testing

The static wiring tests only indicate that the system is wired as
shown in the system drawings. Before the system can be
operated automatically it is necessary to verify that the output
devices and their corresponding input signals can be activated
through the PLC program and that the corresponding software
addresses are correct.

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Manual testing will require a complete documentation package

that relates the control program to the actual field devices.
Documents such as address assignments and wiring diagrams
must reflect any modifications that may have occurred during
the static wiring checks.

Manual testing of the system requires that all valves be stroked

and motors started long enough to be tested for proper rotation
(bumping the motor).

For the manual and the automatic testing, the PLC is placed in
the RUN mode.

The following is a checklist for final program checkout:

• Using the I/O wiring document, verify, against the hard

copy program printout, that every controlled output device
has a programmed output rung of the same address.
• Inspect the hard copy printout for any entry errors that may
have occurred while entering the program. Verify that all
program contacts and internal outputs have valid address
assignments.
• Verify that all timer, counter, and other preset values are
as designed.

Stroke Valves
If the system contains manual control for all valves, the system
is placed in the manual mode. The open and close controls are
used to activate the valves. The corresponding input signals
(open and closed limits) controlled by the valve are monitored.
Only one valve is tested at a time. The following procedure for
testing valve FV-101 assumes that there are panel mounted
indicator lights showing the open and close status for the valve.

1. Check mimic pilot lights. A red light indicates valves are

closed and pumps are off. A green light indicates valves
are open and pumps are on.
2. Open FV-101 (HS101). Observe that the mimic light
changes from red to green. Close FV-101. Observe that
the mimic light changes from green to red.
During the time when a valve is traveling from closed to
open or from open to closed both lights will be ON.

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The PLC simulator contains manual controls for all valves and
motors.

If the system does not contain manual controls for the valves,
the PLC FORCE function is used to enable the PLC outputs
controlling the opening and closing of the valves.

Bump Motors And

Check For Proper
Rotation
Three phase motors must be checked for proper rotation when
energized. If the wires connected to phases A, B, and C are out
of phase the motor may run counter-clockwise instead of
rotating clockwise. In order to test the rotation of the motors,
each motor is started and immediately stopped. When the
motor is started, the rotation is observed. If the rotation is not
correct, the three phase power is removed and two of the phase
wires are reversed. After the wires are changed, the motor is
tested again for proper rotation.

The starting and stopping of the motor is accomplished with

manual controls if available, or the PLC output controlling the
motor is forced ON and then immediately OFF.

System Operation
Under Manual
Control
After all the valves and motors are stroked, the system is tested
under manual control of the processes. Manual control is used
to verify the logic of the control program for correct operation of
all inputs and outputs. In addition, pressure switches and
transmitters are verified for proper operation and settings. As
each phase of the system is tested, it is verified with the
program logic contained in the ladder printout.

Automatic Program Testing

After the system is tested in the manual mode, it is assumed

that it is safe to test the system automatic control mode.

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Although it may not be necessary to start a small system

partially, it is always a good practice to start large systems in
sections. Large systems generally use remote subsystems that
control different sections of the machine or process. Bringing
one subsystem on-line at a time will allow the total system
startup to be performed with maximum safety and efficiency.
Remote subsystems can be temporarily disabled either by
locally removing power or by disconnecting the communications
link with the CPU.

Automatic System
Operation
A mode such as TEST, if available, will allow the control
program to be execute and debugged while the outputs are
disabled. A check of each rung can be done by observing the
status of the output LED indicators or by monitoring the
corresponding output rung on the programming device.
If the controller must be in the RUN mode to update outputs
during the tests, outputs that are not being tested should be
locally disconnected until they are tested. If an MCR or similar
instruction is available, it can be used to bypass execution of
the outputs that are not being tested so that disconnection of
the output devices is not necessary.
Check each rung for correct logic operation and modify the logic
if necessary. A useful tool for debugging the control logic is the
single scan. This procedure will allow users to observe each
rung as every scan is executed under their command.
When all the logic has proven to control the outputs
satisfactorily, remove all temporary rungs that may have been
used. Place the controller in the RUN mode and test the total
system operation. If all procedures have checked correctly,
then full automatic control should operate smoothly.
The startup recommendations and practices that have been
presented in this section are considered good procedures that
will aid in the safe and orderly startup of any programmable
control system. However, depending on the controller that is
being installed, there may be specific startup requirements that
are outlined in the manufacturer’s product manual. The
engineer should be aware of these specific startup procedures,
prior to attempting to startup the controller.

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The PLC program has previously been tested using simulated

input and output conditions during the FAT. It is not necessary
to run the system under automatic control to verify the system
timing and the interlocks.

System timing is checked as each section of the system is run

under automatic control. Timer, counter, and preset settings
are verified under actual process conditions. For example, the
simulator contains timers for controlling mixing time, fill times
and pressure fail time. The times set during the FAT are based
on engineering design but actual process dynamics and
hydraulics may necessitate a change in the time settings.

Interlocks (and alarms) must be verified as part of the

automatic program testing. For example, Pump P-214 is
interlocked with the level in tank T-214. When the system is in
Automatic, Pump P-214 is not permitted to start unless the level
in T-214 is greater than 25 %.

Alarms must be verified to ensure that the system will respond

according to the control program when a malfunction occurs.
The response to the alarm may be only an alarm indication or
equipment may also be stopped.

Turnover System
After the system has been verified in the automatic mode, prior
to turning the system over to the buyer, the following are to be
completed prior to the turnover of the system to the buyer.

1. Modifications and changes to the system drawings must

be documented on the original drawing set and transmitted
to the owner.

2. All modifications to the control logic must be documented

and revised on the original documentation. Copies of
the revised program must be included in the revised
documentation.

After the receipt of all the required documentation and approval

of the system operation the system operation is transferred from
the vendor to the owner.

The Addendum is a Factory Acceptance Test Procedure for the

PLC Simulator.

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GLOSSARY

FAT A Factory Acceptance Test.

static wiring test A test used to indicate that the system is wired as
shown in the system drawing.

validation To check the validity of a process, system, or PLC

program.

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ADDENDUM: FACTORY ACCEPTANCE TEST (FAT) PROCEDURE

FOR A PLC SIMULATOR

Part 1. Mechanical Inspection

Reference Drawings

The reference drawings associated with this project are listed in Figure 3.

ITEM DRAWING SHEET DESCRIPTION

NUMBER
1 422-P&I 03 P&ID Product 1 Blending Process
2 422-LD1 01 Basic Logic Diagram FV101 Manual/Auto Open/Close Logic
3 422-L 01 Symbols Legend
4 422-I/O 01 Simulator PLC Logic Module Assignment
5 422-I/O 02 I/O Arrangement Input Signals Rack 0, Groups 1 and 2
6 422-I/O 03 I/O Arrangement Input Signals Rack 0, Groups 3 and 4
7 422-I/O 04 I/O Arrangement Output and Input Signals, Rack 0 Groups 5 and 6
8 422-I/O 05 I/O Arrangement Future I/O Rack 0 Group 7
9 422-I/O 05 I/O Arrangement Output Signals Rack 1 Groups 1 and 2
10 422-I/O 07 I/O Arrangement Output Signals Rack 1 Groups 3 and 4
11 422-I/O 08 I/O Arrangement Output Signals Rack 1 Groups 5 and 6
12 422-I/O 09 I/O Arrangement Output/Input Signals Rack 1 Group 7/Rack 2 Group
13 422-I/O 10 0

14 422-I/O 11 I/O Arrangement Future I/O Rack 2 Groups 1 and 2

15 422-EWS 01 I/O Arrangement Future I/O Rack 2 Group 3

16 422-EWS 02 Electrical Wiring Schematic Power Distribution

17 422-EWS 03 Electrical Wiring Schematic Power Distribution

18 422-CP 01 Electrical Wiring Schematic Power Distribution

19 422-CP 02 Training Simulator Plans and Elevation

20 422-CP 03 Training Panel Subpanel 1 Layout

21 422-CP 04 Training Simulator Subpanel 2 Layout

22 422-CP 05 Training Simulator Cutout Details

23 422-CP 06 Training Simulator Mimic Panel Arrangement Front View

24 422-CP 07 Training Simulator Mimic Panel Arrangement Rear View

25 422-CP 08 Training Simulator Front Door Layout Front View

Training Simulator Front Panel Layout Rear View

Figure 3. Reference Drawings

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Mechanical Components

Check components in accordance with system diagrams:

• Subpanel 1; components and wiring

• Subpanel 2; components and wiring

• Front panel controls, lights, and indicators

• Rear panel components and wiring

• Mimic panel

• Layout of components

Part 2. System Operation

Part 2 will test the interaction of the front panel controls with the PLC program.

Manual Operation

Initial conditions:

• PL432: Panel power light ON.

• Place System Mode switch (HS335) in the Manual Mode.

• All valves CLOSED.

• All pumps OFF.

1. Check mimic pilot lights. Red light indicates valves are closed and pumps are
off. Green light indicates valves are open and pumps are on.

2. Open FV-101 (HS101). Observe that the mimic light changes from red to green.
Close FV-101. Observe that the mimic light changes from green to red.

NOTE: During the time when a valve is traveling from closed to open or from
open to closed both lights will be ON.

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3. Open FV-102 (HS102). Observe that the mimic light changes from red to green.
Close FV-102. Observe that the mimic light changes from green to red.

4. Open FV-103 (HS103). Observe that the mimic light changes from red to green.
Close FV-103. Observe that the mimic light changes from green to red.

5. Open FV-104 (HS104). Observe that the mimic light changes from red to green.
Close FV-104. Observe that the mimic light changes from green to red.

6. Open FV-108 (HS108). Observe that the mimic light changes from red to green.
Close FV-108. Observe that the mimic light changes from green to red.

7. Start agitator AG-101 (HS112). Relay MS344 (located on rear sub-panel) will
energize and AG-101 mimic light will change from red to green. Stop agitator
AG101. Observe that the mimic light changes from green to red.

8. Start Transfer pump P-106 (HS106). Relay MS350 (located on rear sub-panel)
will energize and P-106 mimic light will change from red to green. Stop Transfer
Pump P-106. Observe that the mimic light changes from green to red.

9. Start Product Loading pump P-214 (HS214). Relay MS346 (located on rear sub-
panel) will energize and P-214 mimic light will change from red to green. Stop
Product Loading pump P-214. Observe that the mimic light changes from green
to red. Pump P-214 is interlocked in the Auto mode so that it will not start unless
the level in TK-214 is greater than 25%. In the manual mode all interlocks are
not used.

10. Open FV-105 (HS105). Observe that the mimic light changes from red to green.
Close FV-105. Observe that the mimic light changes from green to red.

11. Open FV-109 (HS109). Observe that the mimic light changes from red to green.
Close FV-109. Observe that the mimic light changes from green to red.

12. Open FV-110 (HS110). Observe that the mimic light changes from red to green.
Close FV-110. Observe that the mimic light changes from green to red.

13. Open FV-111 (HS111). Observe that the mimic light changes from red to green.
Close FV-111. Observe that the mimic light changes from green to red.

14. Start Recycle Pump P-107 (HS107). Relay MS348 (located on rear sub-panel)
will energize and P-107 mimic light will change from red to green. Stop agitator
AG101. Observe that the mimic light changes from green to red.

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15. Lamp test: Press the TEST push-button located on the mimic. Observe that all
mimic lights will be ON. In addition, the Auto Mode Enabled, Pause Mode, and
Emergency Shutdown lights on the front of the panel will be ON. The Panel
Power light is illuminated all the time and is not part of the lamp test.

The level indicators LI101 and LI214 will be tested when in the AUTO mode.

16. Start transfer pump, P106, product loading pump, P214, recycle pump, P107 and
agitator or AG-101. After all pumps and the agitator are ON, press the
Emergency stop push button. Observe that all pumps are stopped and the ESD
light is ON. Press ESD RESET (HS434) to reset the emergency stop relay. The
ESD light will be OFF. The pumps remain OFF.

Automatic Operation

Wash 1 Cycle - Initial conditions:

• All valves CLOSED.

• Agitator OFF.
• All pumps OFF.
• Turn System Mode switch (HS335) in the AUTO mode.
• Turn Process Selection to Wash 1.
1. Turn AUTO mode switch (HS337) to the START position. Observe that the AUTO
mode light will come ON and valves FV-110 and FV-111 OPEN.

NOTE: There is a 10 second time delay after the system is started before the
AUTO mode light will come ON. This delay is used as an aid for the
training instructor.

2. TK-101 will start to fill. Observe that TK-101 level indication (LI-101) starts to
rise.

3. When the level in TK-101 reaches 20% agitator AG-101 is turned ON.

4. When the level in TK-101 reaches 85% valves FV-110 and FV-111 close and
timer T4:15 (software) will start. Timer T4:15 is set for 90 seconds.

5. After T4:15 completes its timing interval, valve FV-109 OPENS.

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6. When FV-109 is fully open Recycle Pump P-107 is started.

7. After P-107 is started the level in tank TK-101 decreases to 0. When the level in
TK-101 reaches 20% Agitator AG-101 is turned OFF. When the level in TK-101
reaches 0, valve FV-109 is CLOSED and P-107 is turned OFF.

8. The AUTO MODE ENABLED light is turned OFF. The cycle is complete.

The Batch Process involves two steps; the Mix Cycle and the Transfer Cycle.

Mix cycle - Initial conditions:

• All valves CLOSED.

• Agitator AG-101 OFF.

• All pumps OFF.

• Turn System Mode switch (HS335) in the AUTO mode.

• Turn Process Selection to Batch.

1. Turn AUTO mode switch (HS337) to the START position. Observe that the AUTO
mode light will come ON. Valve FV-101 OPENS.

NOTE: There is a 10 second time delay after the system is started before the
AUTO mode light will come ON. This delay is used as an aid for the
training instructor.

2. TK-101 will start to fill. Observe that LI-101 rises to ≅ 38% indication. As the
level in TK-101 rises observe that agitator AG-101 turns ON when the level
reaches 20%.
3. When the level in TK-101 reaches 38% valve FV-101 CLOSES and FV-102
OPENS.

4. When the level in TK-101 reaches 75% valve FV-102 CLOSES.

5. After both ingredients are added internal software timer T4:001 is enabled and
starts its timing cycle.
6. After T4:001 completes its 75 second timing cycle the agitator is turned OFF the
alarm is sounded, and the pause light starts to pulse ON and OFF.

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7. Press the ACK (acknowledge) push button to silence the horn. The pause light
remains pulsing.

The process will remain in this state until the RESUME push button (HS136) is
pressed.

NOTE: The pause cycle is part of the PLC program and is used to allow time
to test the product after it has been mixed. The program will remain in
the pause mode until the Resume push-button is pressed.

Transfer Cycle

8. Push the resume push button to start the transfer cycle. The pause light will be
turned OFF.

9. Observe that valves FV-103, FV-104, and FV-108 are opened.

10. When valves FV-103, FV-104, and FV-108 are fully open, pump P-106 is started
and the product is transferred to storage tank TK-214. As the product is
transferred the level in TK-101 decreases and the level in TK-214 increases.

11. When TK-101 is empty, all valves are closed and P-106 is stopped. The reading
on TK-214 level indicator should be ≅ 25% and TK-101 level indicator zero.

Wash 2 Cycle - Initial conditions:

• Turn System mode switch to AUTO.

• Turn Process selection to Wash 2.

• All valves CLOSED.

• Agitator OFF.

• All pumps OFF.

1. Turn AUTO mode switch (HS337) to the START position. Observe that the AUTO
mode light will come ON and valves FV-110 and FV-111 OPEN.

NOTE: There is a 10 second time delay after the system is started before the
AUTO mode light will come ON. This delay is used as an aid for the
training instructor.

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2. TK-101 will start to fill. Observe that the TK-101 level indication (LI-101) starts to
rise.

3. When the level in TK-101 reaches 20% agitator AG-101 is turned ON.

4. When the level in TK-101 reaches 85% valves FV-110 and FV-111 close and
timer T4:15 (software) will start. Timer T4:15 is set for 180 seconds.

5. After T4:15 completes its timing interval valves FV-103, FV-104, and FV-105
OPEN.

6. When valves FV-103, FV-104, and FV-105 are fully open transfer pump P-106 is
started.

7. After P-106 is started the level in tank TK-101 decreases to 0. Agitator AG-101
is turned OFF when the level decreases to 25%. When the level in TK-101
reaches 0, all valves are CLOSED and P-106 turned OFF.

8. The AUTO MODE ENABLED light is turned OFF. The cycle is complete.

Unloading Cycle - The Product Loading Pump, P-214, is used to transfer the product
from the storage tank TK-214. When the System Mode switch is in the automatic
position the level in TK-214 must be greater than 20% before P-214 is permitted to run.
Also, Pump, P-214, also has a low level interlock that will stop the pump when the level
in TK-214 is zero %. When the System Mode switch is in Manual there are no
interlocks and the pump is permitted to run.

Initial conditions:

• Turn System Mode switch to Auto

• Level in TK-214 greater than 20%

1. Start Product Loading Pump, P-214. With the product loading pump ON the level
in TK-214 will decrease to zero %. When the level reaches zero % Product
Loading Pump P-214 will turn OFF.
2. With the level in TK-214 at zero % start P-214. The pump should not start.
3. Turn the System Mode switch to Manual.
4. Start Product Loading pump P-214 (HS214). Relay MS346 (located on rear sub-
panel) will energize and P-214 mimic light will change from red to green. Stop
Product Loading pump P-214. Observe that the mimic light changes from green
to red.

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Ambient air temperature high alarm for customer use. The PLC output is wired to
terminals TB7-27 and TB7-28.

1. Connect an ohmmeter between terminals TB7-27 and TB7-28. The resistance

reading should be 0 ohms. There should be a short circuit.

2. Using the PLC, force off output O:013/07 ON (Rung P2/24). The resistance
reading should be an open circuit (infinite Ω).

Battery low test is to test the power level of the battery.

1. With the PLC in the RUN mode, remove the battery from the PLC. The PLC fault
light on the mimic should start to pulse.

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