ADVANTAGES OF CONTROLLER BASED SYSTEM

OVER CONVENTIONAL ELECTRICAL SYSTEM: A CASE

STUDY

AJAY SINGH
Dy. DIRECTOR OF MINES SAFETY (ELEC) EASTERN ZONE
MINISTRY OF LABOUR & EMPLOYMENT
GOVERNMENT OF INDIA

ABSTRACT: It’s a proven fact that, by clubbing electrical and electronic

disciplines, there could be considerable savings in terms of improved operation
of equipments, easy maintainability, enhanced safety, reduced running cost etc.
One such job was done in one of HEMM (Heavy Earth Moving Machinery) by
replacing the conventional Electrical scheme with that of PLCs (Programmable
Logic Controllers).

At Ramagundam Open Cast Project-II, with about Rs 1000 Crores worth

of investment, of Public Sector namely m/s S.C.C.L. (Singareni Collieries
Company Limited), most of the other equipments like Conveyors (20 nos. in
total), Crushers (4 nos.), Spreaders (3 nos.), have been controlled and operated
by PLCs (Programmable Logic Controllers), with the exception of Tripper car,
which made use of conventional electricals as mentioned above.

An in-house project was undertaken, to replace the conventional electrical

scheme with that of logical controllers, by preparing the equivalent logics
individually. The final outcome was fantastic, as there were all round benefits;
ease of maintenance, lesser running reports, enhanced availability of equipment,
low operating cost, incorporation of additional features, etc.

INTRODUCTION: Originally unlike spreaders, crushers, & conveyors, the tripper

cars which operate in conjunction with spreaders and act as variable discharge
point for Over Burden, were commissioned using conventional components like
plenty of contactors, timers and set reset relays in addition to bulk of electrical
wiring. This arrangement though working, was leading to lot of avoidable reports
due to mal-function/ failure of one or the other component. Moreover a lot of time
used to get wasted to rectify these reports due to complexity of electricals
involved.

Other equipments like conveyor, crushers and spreaders utilize PLCs

(programmable logic controllers) for their operation which makes the scheme
reliable as the minimum no of components along with meager wiring are used
which not only minimizes the reports but also results in easy trouble shooting due
to involvement of minimum components.
The scheme of tripper car is modified to make it in line with other equipments
by commissioning PLC in its E-house. The installation of PLC has straightaway
resulted in reduction of electrical wiring by about 70%, removal of about 90 nos.
of auxiliary contactors, 20 nos. of set-reset relays, and about 30 nos. timers (both
on/off delays). Moreover the grease lubrication monitoring unit being used to
automatically switch on and off the grease lubrication pump is no more required
as the same objective is achieved by suitably programming the same in PLC.
The imported angle operated limit switch being used to cut the rotor resistors (by
giving command to concerned power contactors) depending upon the angle of
pendulum arm of cable reel drum is removed by incorporating the same in PLC.
This is achieved by providing a certain time delay in PLC for the stepping in of
rotor contactors during cable winding. The brief summary of various benefits
reaped through this modification is enumerated hereunder:

1. Removal of about 90 nos of auxiliary contactors,

2. Removal of about 30 nos of various on/off delay timers,
3. Removal of about 20 nos of set reset relays,
4. About 70% reduction in wiring,
5. Removal of grease monitoring unit,
6. Removal of angle operated limit switch,
7. Reduced maintenance, easy trouble shooting and improved reliability due
to above mentioned points,
8. Tamperproof scheme.

Additionally some additional features like automatic switching off of indoor

lights after half an hour even if left in ON state is being incorporated as an energy
conservation measure.

SCHEME: The program of PLC is so developed that the same effects are
achieved involving minimum no. of components. The conventional items like
timers, contactors, set-reset relays etc are removed by incorporating the same in
PLC. 4 nos. of 32*24 volt DC input and 3 nos. of 32*24 volt DC output modules,
1no each of CPU and power supply modules along with 1 no back
plane( mounting plate) are used to accomplish the required task. All the
necessary preconditions are directly extended to PLC Input module without the
use of most of the contactors, timers etc which were earlier used to achieve the
same task. Depending upon the availability of input conditions, command is
issued through output module to the concerned drive/safety to function. The
preconditions available at Input module are compared with the program loaded in
CPU. In case of any deviation from the desired/safe operating condition, which
can happen due to actuation of concerned safety/operational limit switches or
tripping of concerned relays etc, concerned operation is prohibited by virtue of
blocking of relevant output command. The safety of machine is not at all
compromised and in fact additional safeties are included in some of the
applications.

The task is accomplished by almost nil investment as the modification is

managed using modules supplied as initial spares, however, to procure these
modules afresh, there could be initial outlay of about Rs 20,000,00.00 ( Rs
Twenty Lakhs Only).

COST BENEFIT ANALYSIS:

s.no. SPARES REMOVED DUE TO COST OF SPARES

MODIFICATION
1. Removal of about 90 nos of Auxiliary Approx. Rs 1,00,000.00
contactors
2. Removal of about 20 nos of set reset relays Approx Rs 50,000.00
3. Removal of about 30 nos of on/off delay Approx Rs 50,000.00
timers
4. Removal of angle operated switch Approx. Rs 1,00,000.00
5. Removal of grease monitoring unit Approx Rs 50,000.00
TOTAL: Approx Rs 3,50,000.00

CONCLUSION: Through this paper an effort is made to demonstrate that by

switching over to PLC from conventional electrical schemes may result in lot of
benefits in terms of inventory, enhanced availability due to reduction in
breakdowns and promptness in attending reports. All this is achieved without
compromising the safety a bit. In fact some additional safety features are
included in some of the applications.