What skills are required to integrate PLC with plant systems and equipment?

1 Basic PLC programming

You need to know how to program PLCs using one or more of the standard languages defined by the International Electrotechnical Commission (IEC). These include ladder logic, function block diagram, structured text, instruction list, and sequential function chart. You also need to know how to use PLC software tools, such as editors, debuggers, simulators, and monitors. You should be able to write, test, and troubleshoot PLC programs that meet the requirements and specifications of the plant systems and equipment.

2 PLC communication protocols

You need to know how to communicate with PLCs using various protocols, such as Ethernet, serial, Modbus, Profibus, and Profinet. You should be able to configure, connect, and diagnose PLC networks and devices. You should also be familiar with the data formats, addressing schemes, and error handling methods of each protocol. You should be able to use PLC communication tools, such as scanners, analyzers, and converters.

3 PLC hardware and wiring

You need to know how to select, install, and maintain PLC hardware and wiring. You should be able to identify the types, features, and functions of PLC components, such as CPUs, power supplies, input/output modules, memory cards, and batteries. You should also be able to wire and connect PLCs to sensors, actuators, switches, relays, and other plant equipment. You should be able to use PLC hardware and wiring tools, such as multimeters, oscilloscopes, crimpers, and strippers.

4 PLC safety and security

You need to know how to ensure the safety and security of PLCs and plant systems and equipment. You should be aware of the potential hazards and risks of working with PLCs, such as electric shocks, fires, explosions, and cyberattacks. You should also be able to apply the relevant standards and regulations for PLC safety and security, such as the National Electrical Code (NEC), the Occupational Safety and Health Administration (OSHA), and the International Society of Automation (ISA). You should be able to use PLC safety and security tools, such as lockout/tagout devices, surge protectors, firewalls, and encryption.

6 Problem-solving and troubleshooting skills

You need to have good problem-solving and troubleshooting skills to integrate PLCs with plant systems and equipment. You should be able to identify, analyze, and resolve any issues or errors that may arise during the integration process. You should also be able to document and report the problems and solutions. You should be able to use problem-solving and troubleshooting tools, such as logic analyzers, fault finders, and diagnostic software.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?