PLC technicians design, program, repair, and maintain

programmable logic controller 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 ...

(PLC) systems used within manufacturing and service industries ranging from industrial packaging to commercial car washes and

traffic lights Traffic lights, traffic signals, or stoplights – also known as robots in South Africa, Zambia, and Namibia – are signaling devices positioned at road intersections, pedestrian crossings, and other locations in order to control the flow o ...

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 Industrial process control (IPC) or simply process control is a system used in modern manufacturing which uses the principles of control theory and physical industrial control systems to monitor, control and optimize continuous Industrial processe ...

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

valve A valve is a device or natural object that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized solids, or Slurry, slurries) by opening, closing, or partially obstructing various passageways. Valves are technically Pip ...

s, actuators and positioners to manipulate the process medium. They install and terminate electrical,

pneumatic Pneumatics (from Greek 'wind, breath') is the use of gas or pressurized air in mechanical systems. Pneumatic systems used in Industrial sector, industry are commonly powered by compressed air or compressed inert gases. A centrally located a ...

, and fluid connections. They also work on network and signal transmission systems such as fibre optic and wireless. Along with the

calibration In measurement technology and metrology, calibration is the comparison of measurement values delivered by a device under test with those of a calibration standard of known accuracy. Such a standard could be another measurement device of known ...

, 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 System A distributed control system (DCS) is a computerized 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 contro ...

s (DCSs), Supervisory Control & Data Acquisition (

SCADA SCADA (an acronym for supervisory control and data acquisition) is a control system architecture comprising computers, networked data communications and graphical user interfaces for high-level supervision of machines and processes. It also cove ...

), and

Human Machine Interface In the industrial design field of human–computer interaction, a user interface (UI) is the space where interactions between humans and machines occur. The goal of this interaction is to allow effective operation and control of the machine fro ...

s (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 Pressure (symbol: ''p'' or ''P'') is the force applied perpendicular to the surface of an object per unit area over which that force is distributed. Gauge pressure (also spelled ''gage'' pressure)The preferred spelling varies by country and eve ...

, flow,

temperature Temperature is a physical quantity that quantitatively expresses the attribute of hotness or coldness. Temperature is measurement, measured with a thermometer. It reflects the average kinetic energy of the vibrating and colliding atoms making ...

, level, motion, force, and chemical composition. 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 Hydraulics () is a technology and applied science using engineering, chemistry, and other sciences involving the mechanical properties and use of liquids. At a very basic level, hydraulics is the liquid counterpart of pneumatics, which concer ...

pneumatics Pneumatics (from Greek 'wind, breath') is the use of gas or pressurized air in mechanical systems. Pneumatic systems used in industry are commonly powered by compressed air or compressed inert gases. A centrally located and electrically- ...

robotics Robotics is the interdisciplinary study and practice of the design, construction, operation, and use of robots. Within mechanical engineering, robotics is the design and construction of the physical structures of robots, while in computer s ...

, DCS,

, electrical circuits, electrical machinery and

human-machine interface In the industrial design field of human–computer interaction, a user interface (UI) is the space where interactions between humans and machines occur. The goal of this interaction is to allow effective operation and control of the machine fro ...

s. Typical courses include math, communications, circuits, digital devices, and electrical controls. Other courses include robotics, automation,

electrical motor An electric motor is a machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate Laplace force i ...

controls, programmable logic controllers, and

computer-aided design Computer-aided design (CAD) is the use of computers (or ) to aid in the creation, modification, analysis, or optimization of a design. This software is used to increase the productivity of the designer, improve the quality of design, improve c ...

. 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 Critical thinking is the process of analyzing available facts, evidence, observations, and arguments to make sound conclusions or informed choices. It involves recognizing underlying assumptions, providing justifications for ideas and actions, ...

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. These programs can be completed at Colleges and Universities in either an in-class or online format. Some Colleges, such as

George Brown College The George Brown College of Applied Arts and Technology is a public, fully accredited college (Canada), college of applied arts and technology with three campuses in downtown Toronto (Ontario, Canada). Like many other colleges in Ontario, George ...

, offer an online PLC Technician program that uses simulation software, PLCLogix, to complete PLC lab projects and assignments.Online PLC Technician program
/ref> 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 A college (Latin: ''collegium'') may be a tertiary education, tertiary educational institution (sometimes awarding academic degree, degrees), part of a collegiate university, an institution offering vocational education, a further educatio ...

and

Universities A university () is an educational institution, institution of tertiary education and research which awards academic degrees in several Discipline (academia), academic disciplines. ''University'' is derived from the Latin phrase , which roughly ...

, 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 The Electronics Technicians Association, International, Inc. (doing business as ETA International) is a US-based not-for-profit 501(c)(6) trade association founded in 1978. The association provides certifications in industries such as basic elec ...

Robotics Industries Association The Association for Advancing Automation (A3) is an international trade group that serves the robotics industry. It was founded in 1974 and is headquartered in Ann Arbor, Michigan. The organization is involved in safety standards for robots, and sp ...

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 A motor drive is a physical system that includes a motor. An adjustable speed motor drive is a system that includes a motor that has multiple operating speeds. A variable speed motor drive is a system that includes a motor that is continuously v ...

, 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 Electric power distribution is the final stage in the delivery of electricity. Electricity is carried from the transmission system to individual consumers. Distribution substations connect to the transmission system and lower the transmission v ...

food processing Food processing is the transformation of agricultural products into food, or of one form of food into other forms. Food processing takes many forms, from grinding grain into raw flour, home cooking, and complex industrial methods used in the mak ...

mining Mining is the Resource extraction, extraction of valuable geological materials and minerals from the surface of the Earth. Mining is required to obtain most materials that cannot be grown through agriculture, agricultural processes, or feasib ...

, 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: * Automation equipment wholesalers * Industrial manufacturing companies * Water Treatment plants * Nuclear, Wind, Thermal, and Hydro Electric Power companies * Pharmaceutical companies * Mining, petrochemical and natural gas companies * Pulp and paper processing companies

References

{{Reflist Programmable logic controllers Technicians

Scope of work

Education, training and skills

Career opportunities

See also

References