PLC technician

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PLC technicians design, program, repair, and maintain programmable logic controller (PLC) systems used within manufacturing and service industries ranging from industrial packaging to commercial car washes and traffic lights.

Contents

Scope of work

PLC technicians are knowledgeable in overall plant systems and the interactions of processes. They install and service a variety of systems including safety and security, energy delivery (hydraulic, pneumatic and electrical), communication, and process control systems. They also install and service measuring and indicating instruments to monitor process control variables associated with PLCs, and monitor the operation of PLC equipment. PLC technicians work with final control devices such as valves, actuators and positioners to manipulate the process medium. They install and terminate electrical, pneumatic, and fluid connections. They also work on network and signal transmission systems such as fibre optic and wireless. [1]

Along with the calibration, repair, adjustment, and replacement of components, PLC technicians inspect and test the operation of instruments and systems to diagnose faults and verify repairs. They establish and optimize process control strategies, and configure related systems such as Distributed Control Systems (DCSs), Supervisory Control & Data Acquisition (SCADA), and Human Machine Interfaces (HMIs). PLC technicians maintain backups, documentation, and software revisions as part of maintaining these computer-based control systems. Scheduled maintenance and the commissioning of systems are also important aspects of the work. PLC technicians consult technical documentation, drawings, schematics, and manuals. They may assist engineering in plant design, modification and hazard analysis, and work with plant operators to optimize plant controls.

PLC technicians use hand, power, and electronic tools, test equipment, and material handling equipment. They work on a variety of systems including primary control elements, transmitters, analyzers, sensors, detectors, signal conditioners, recorders, controllers, and final control elements (actuators, valve positioners, etc.). These instruments measure and control variables such as pressure, flow, temperature, level, motion, force, and chemical composition. [2] PLC systems designed and maintained by PLC technicians range from high-speed robotic assembly to conveyors, to batch mixers, to DCS and SCADA systems. PLC systems are often found within industrial and manufacturing plants, such as food processing facilities. Alternate job titles include PLC engineer, Automation Technician, Field Technician, or Controls Technician.

Education, training and skills

PLC technician educational courses and programs integrate PLC programming with mechanics, electronics and process controls, They also commonly include coursework in hydraulics, pneumatics, robotics, DCS, SCADA, electrical circuits, electrical machinery and human-machine interfaces. Typical courses include math, communications, circuits, digital devices, and electrical controls. Other courses include robotics, automation, electrical motor controls, programmable logic controllers, and computer-aided design. [3] When performing their duties, PLC technicians must comply with federal, jurisdictional, industrial, and site-specific standards, codes, and regulations. They must ensure that all processes operate and are maintained within these set standards, codes, and regulations. Keeping up-to-date with advances in technology in the industry is important. Key attributes for PLC Technicians are critical thinking skills, manual dexterity, mechanical aptitude, attention to detail, strong problem-solving skills, communication skills, and mathematical and scientific aptitude.

Employers generally prefer applicants who have completed a PLC technician certificate or related associate degree. [4] These programs can be completed at Colleges and Universities in either an in-class or online format. Some Colleges, such as George Brown College, offer an online PLC Technician program that uses simulation software, PLCLogix, to complete PLC lab projects and assignments. [5] Certification by accredited schools and third-party organizations can enhance employment opportunities and keep PLC technicians current and up-to-date. In addition to Colleges and Universities, other organizations and companies also offer credential programs in PLCs, including equipment manufacturers such as Rockwell and professional associations, such as the Electronics Technicians Association, Robotics Industries Association and the Manufacturing Skill Standards Council.

Career opportunities

PLC technicians install and repair industrial electronic equipment (including input/output networks, data highways, variable speed drives, and process control equipment) and write PLC programs for a wide variety of automated control systems, ranging from simple on–off controls to robotics. PLC technicians also find employment in the industrial engineering field where they are actively involved in the design and implementation of PLC control systems.

Career opportunities for PLC Technicians include a wide range of manufacturing and service industries such as automotive, pharmaceutical, power distribution, food processing, mining, and transportation. Other career prospects include areas such as machine assembly, troubleshooting, and testing, systems integration, application support, maintenance, component testing and assembly, automation programming, robot maintenance and programming, technical sales and services.

PLC Technicians work mainly indoors, on the plant floor and sometimes in cramped conditions. They may be required to stand for prolonged periods of time and be exposed to high noise, fumes and heat levels. Because this is such an important job, they must pay close attention to safety and may be called out in emergencies. Constant learning may be required to keep up with new technology.

Primarily work in this area is full-time and can be in shifts. Employers who hire PLC Technicians include:

See also

Related Research Articles

<span class="mw-page-title-main">Programmable logic controller</span> Programmable digital computer used to control machinery

A programmable logic controller (PLC) or programmable controller is an industrial computer that has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, machines, robotic devices, or any activity that requires high reliability, ease of programming, and process fault diagnosis. Dick Morley is considered as the father of PLC as he had invented the first PLC, the Modicon 084, for General Motors in 1968.

Instrumentation a collective term for measuring instruments that are used for indicating, measuring and recording physical quantities. The term has its origins in the art and science of scientific instrument-making.

Supervisory control and data acquisition (SCADA) is a control system architecture comprising computers, networked data communications and graphical user interfaces for high-level supervision of machines and processes. It also covers sensors and other devices, such as programmable logic controllers, which interface with process plant or machinery.

<span class="mw-page-title-main">Automation</span> Use of various control systems for operating equipment

Automation describes a wide range of technologies that reduce human intervention in processes, namely by predetermining decision criteria, subprocess relationships, and related actions, as well as embodying those predeterminations in machines. Automation has been achieved by various means including mechanical, hydraulic, pneumatic, electrical, electronic devices, and computers, usually in combination. Complicated systems, such as modern factories, airplanes, and ships typically use combinations of all of these techniques. The benefit of automation includes labor savings, reducing waste, savings in electricity costs, savings in material costs, and improvements to quality, accuracy, and precision.

A distributed control system (DCS) is a computerised control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory control. This is in contrast to systems that use centralized controllers; either discrete controllers located at a central control room or within a central computer. The DCS concept increases reliability and reduces installation costs by localising control functions near the process plant, with remote monitoring and supervision.

<span class="mw-page-title-main">Control system</span> System that manages the behavior of other systems

A control system manages, commands, directs, or regulates the behavior of other devices or systems using control loops. It can range from a single home heating controller using a thermostat controlling a domestic boiler to large industrial control systems which are used for controlling processes or machines. The control systems are designed via control engineering process.

An industrial process control in continuous production processes is a discipline that uses industrial control systems to achieve a production level of consistency, economy and safety which could not be achieved purely by human manual control. It is implemented widely in industries such as automotive, mining, dredging, oil refining, pulp and paper manufacturing, chemical processing and power generating plants.

<span class="mw-page-title-main">Yokogawa Electric</span>

Yokogawa Electric Corporation is a Japanese multinational electrical engineering and software company, with businesses based on its measurement, control, and information technologies.

<span class="mw-page-title-main">Industrial Ethernet</span> Use of Ethernet in an industrial environment

Industrial Ethernet (IE) is the use of Ethernet in an industrial environment with protocols that provide determinism and real-time control. Protocols for industrial Ethernet include EtherCAT, EtherNet/IP, PROFINET, POWERLINK, SERCOS III, CC-Link IE, and Modbus TCP. Many industrial Ethernet protocols use a modified Media Access Control (MAC) layer to provide low latency and determinism. Some microcontrollers such as Sitara provide industrial Ethernet support.

Power-system automation is the act of automatically controlling the power system via instrumentation and control devices. Substation automation refers to using data from Intelligent electronic devices (IED), control and automation capabilities within the substation, and control commands from remote users to control power-system devices.

In control theory, Advanced process control (APC) refers to a broad range of techniques and technologies implemented within industrial process control systems. Advanced process controls are usually deployed optionally and in addition to basic process controls. Basic process controls are designed and built with the process itself, to facilitate basic operation, control and automation requirements. Advanced process controls are typically added subsequently, often over the course of many years, to address particular performance or economic improvement opportunities in the process.

An industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and interactive distributed control systems (DCSs) with many thousands of field connections. Control systems receive data from remote sensors measuring process variables (PVs), compare the collected data with desired setpoints (SPs), and derive command functions that are used to control a process through the final control elements (FCEs), such as control valves.

The following outline is provided as an overview of and topical guide to automation:

A sequence of events recorder (SER) is an intelligent standalone microprocessor based system, which monitors external inputs and records the time and sequence of the changes. Sequence of events recorders usually have an external time source such as a GPS or radio clock. When wired inputs change state, the time and state of each change is recorded.

Odo Josef Struger was an Austrian pioneer in modern-day automation.

Manufacturing execution systems (MES) are computerized systems used in manufacturing to track and document the transformation of raw materials to finished goods. MES provides information that helps manufacturing decision-makers understand how current conditions on the plant floor can be optimized to improve production output. MES works as real-time monitoring system to enable the control of multiple elements of the production process.

An enterprise appliance transaction module (EATM) is a device, typically used in the manufacturing automation marketplace, for the transfer of plant floor equipment and product status to manufacturing execution systems (MES), enterprise resource planning (ERP) systems and the like.

Instrumentation and control engineering (ICE) is a branch of engineering that studies the measurement and control of process variables, and the design and implementation of systems that incorporate them. Process variables include pressure, temperature, humidity, flow, pH, force and speed.

<span class="mw-page-title-main">Automation technician</span> Profession

Automation technicians repair and maintain the computer-controlled systems and robotic devices used within industrial and commercial facilities to reduce human intervention and maximize efficiency. Their duties require knowledge of electronics, mechanics and computers. Automation technicians perform routine diagnostic checks on automated systems, monitor automated systems, isolate problems and perform repairs. If a problem occurs, the technician needs to be able to troubleshoot the issue and determine if the problem is mechanical, electrical or from the computer systems control ling the process. Once the issue has been diagnosed, the technician must repair or replace any necessary components, such as a sensor or electrical wiring. In addition to troubleshooting, Automation technicians design and service control systems ranging from electromechanical devices and systems to high-speed robotics and programmable logic controllers (PLCs). These types of systems include robotic assembly devices, conveyors, batch mixers, electrical distribution systems, and building automation systems. These machines and systems are often found within industrial and manufacturing plants, such as food processing facilities. Alternate job titles include field technician, bench technician, robotics technician, PLC technician, production support technician and maintenance technician.

Operational technology (OT) is hardware and software that detects or causes a change, through the direct monitoring and/or control of industrial equipment, assets, processes and events. The term has become established to demonstrate the technological and functional differences between traditional information technology (IT) systems and industrial control systems environment, the so-called "IT in the non-carpeted areas".

References

  1. ↑ Cox, Richard (2006) Technician’s guide to Programmable Logic Controllers, 3rd Edition, P.44
  2. ↑ PLC Technician overview
  3. ↑ Typical Competency requirements
  4. ↑ Employment statistics
  5. ↑ Online PLC Technician program
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