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INDUSTRIAL TRAINING
Submitted for partial fulfillment of award of B.Tech Degree
2011-2012
SUBMITTED TO
SUBMITTED BY
Neha Dhanuka
0813331053
ACKNOWLEDGEMENT
At this very outset I sincerely acknowledge with gratitude the guidance and support rendered to me by different people without which this training would not have been materialized. Moving in this direction, I grabbed the opportunities offered to me by Mr.K.N.Pandey and Mr.H.R.Singh to do my summer training in the Fabrication-Electrical Department of HINDALCO INDUSTRIES LTD., Renukoot. I would also like to thank Mr.Gaurav Singh and Mr.Dhananjai Singh whose timely guidance and assistance kept me in the right way and direction throughout the training period. Lastly, I owe a considerable depth to all the employees of Hindalco Parivar, especially the Fabrication Department who spared their precious time to answer my queries and thus helping in my training.
6.1 Ladder Logic 6.2 Sequential flow Chart 6.3 Structured text 7. PLC Communication 8. A Level Application 9. Conclusion and Recommendations 10. References 11. Glossary
21 22 22 23 25 27 28 29
INTRODUCTION
Project report-I, which I submitted, covered basically the first half of our practice schoolI that is orientation session at HINDALCO, Renukoot. In project report-II I have tried to cover what I have learnt in the second half of my stay at HINDALCO. After the orientation session, I was very keen to know how the company is able to control such a large factory with very high accuracy. I tried to enquired about it from some engineers and then I got my answer in a short form i.e. PLC.1 I also came to know about its efficiency and importance in process industry. Then I decided that I would do a project related to PLC. The objectives of preparing this report are to know general PLC issues and understand the operation of a PLC. Control engineering has evolved over time. In the past, humans were the main methods for controlling the system. More recently electricity has been used for control and early electrical control was based on relays. These relays allows power to be switched on and off without a mechanical switch. It is common to use relays to make simple logical control decisions. The development of low cost computer has brought the most recent revolution, the Programmable Logic Controller (PLC). The advent of PLC began in the 1970s and has become the most common choice for manufacturing controls. PLCs have been gaining popularity on the factory floor and will probably remain predominant for some time to come. Most of this is because of advantages they offer. For example it is cost effective for controlling complex systems, flexible and can be reapplied to control other systems quickly and easily etc.. I was given brief and effective introduction of PLC, its parts and its functioning by staff in the electrical department. I was also taken to see the PLCs hardware and how it is controlled. A short class of PLC was also held with other trainees to clear the doubts related to PLC. Interaction with other trainees resulted in exchange of ideas, which have helped, a lot in making the report. A book written by Hugh Jack on PLC provided by department was a great help in understanding of the topic and preparing the report.
Manual control has its own limitation with regard to mass production technique and hence cannot provide the customer with quality goods at an affordable price. Safety and efficient use of raw material and energy are all subject to correctness and accuracy of human action.
2.2.2 Hardwire Logic Control: This was considered to be first step toward automation. Here the contactor and relays together with timers and counters were used in achieving the desired level of automation. Limitations: Bulky and complex wiring. Involves lots of rework to implement change in control logic. The designing be started only when task was completely defined. This leads to longer project time. Requires repair and maintenance too frequently.
2.2.3 Electronic Control: With the advance of electronics, the logic gates and further the microprocessors started replacing the relays and auxiliary contactor in the control circuits. It is more compact than hard-wired control circuitry. Required lesser maintenance. More reliable, energy saving. Lesser response time. Reduced wiring and space requirements.
2.3 Advantages
Advantage of PLC over conventional Relay Logic Control: Relay logic is bulky needs more space while PLC logic system is quite compact. Relay Logic needs a lot of hardwire and their maintenance while in PLC logic hardwire flags replaced by software flags. Any change in Relay logic needs allots of jobs e.g. cable pulling, drilling, relay fixing, wiring etc. it can only accomplish during shutdown of machine, which tends production loss, or unavailability of machine. While in PLC during machine running condition we can carry out any changing jobs in online editing mode. In Relay logic manual mistakes occurs while in PLC logic it got less chances. PLC is quite operation friendly. PLC do not needs much maintenance requirement in compression of Relay logic. Wear and tear occurs in Relay logic, which is not encountered in PLCs. Fault finding in PLC is quite simple compared to relay logic. PLC operation is much reliable compared to relay logic. PLC logic is less accident-prone compared to relay logic. Timers, Counters are software configurable and have a wide range, which is in built in PLC software while these things in relay logic needs as extra module and have extra expanses. Easier storage, archiving and documentation; this is due to its capability with PC AT, Printer, Floppy etc. Tremendous Flexibility: 1. To implement changes in control logic no rewiring is required hence considerable time is saved. 2. PLC can carry out complex function such as generation of time delays, Counting, comparing, arithmetic operations etc.
3. Online as well as offline programming is possible without disturbing the process. 4. High processing speed and great flexibility in the processing of both analog and digital signals. 5. Suitable for close loop task with several loops. Ease of maintenance: 1. Modular replacement 2. Easy trouble shooting. 3. Error diagnostics with programmable unit. Energy saving: - Average power consumption is just 1/10th of power consumed by an equivalent relay logic control. Communication Capabilities: - The PLC can communicate with other PLCs, auxiliary devices like PC, printer etc. or other compatible devices like drives. In todays working environment, the communication capabilities are a prerequisite for any control and automation task. Shorter Project Time: - The hardwired control system can be constructed only after the task is fully defined. In the PLC, however, the construction of the controller and wiring are independent of control program definition. This means that the total hardware is standard and desired control is achieved through program
PARTS OF PLC
The PLC is basically a programmed interface between the field input elements like Limit switches, sensors, transducers, push-buttons etc and the final control elements like Actuators, Solenoid valves, dampers, drives, LEDs, hooters etc.. This interface called as Programmable Logic Controller or to be precise, Programmable Controller consists of the following: 1. Input Modules. 2. CPU with processor and program memory. 3. Output modules. 4. Bus system. 5. Power supply.
Depending upon the nature of input signal coming from the field, the input module could be: Analog Input Module Digital Input Module The typical analog current input modules are 4 to +-20 mA and analog voltage input modules are 0 to +- 50 mV, 0 to +- 500 mV and 0 to +- 10 V. The typical digital input modules are 24V DC, 120V AC and 230V AC.
3.1.2 Central Processing Unit: The Central Processing Unit or CPU consists of the following blocks: Arithmetic Logic Unit (ALU) Program memory Process image memory (internal memory of CPU) Internal timers and counters Flags The heart of CPU is its microprocessor /microcontroller chip. The working of CPU is fully controlled by the instructions / program stored in user program memory. The user program directs and controls the CPUs working. The user based on the control logic required for the control and automation task prepares this program. 3.1.3 Arithmetic Logic Unit (ALU): ALU is the organizer of the PLC. The following operations are carried out by ALU: It organizes the input of external signals and data. It performs logic operation with the data.
It performs calculations. It takes account of the value of internal timers and counters. It takes account of the signal states of stored in the flags. It stores the signal states of the input in the Process Input Image (internal Memory of CPU) before each program scanning cycle. It stores the result of the logic operation in the Process Output Image (internal Memory of CPU) during the program scan. It organizes the output of the result.
3.1.4 Output Module: The output module acts as a link between the CPU and the output devices located in the field. The field devices known as actuators could be relays, contactors, lamps, motorised potentiometers, actuators, solenoid valves, dampers etc. These devices actually control the process. The output module converts the output signal delivered by CPU into an appropriate voltage level suitable for the output field device. The voltage signal provided by CPU could be 5V or 9V, but the output module converts this voltage level into say 24VDC, 120VAC or 230VAC. Thus the output module on receiving signal from the processor switches voltage to the respective output terminals. This makes the actuators (i.e. contactors, relays etc) or indicating lights etc connected to the terminal to turn ON or OFF. Like input module, an output module could be an analog or digital.
The selection is based on the voltage rating of the field output devices. If the output device is analog then analog output module is required and if its digital like contactor coil or a lamp then digital output module is required.
Typical analog output modules have the ratings of 4 to +-20 mA or 0 to +-10 V and the digital modules have 24VDC, 120VAC, 230VAC or relay output.
3.1.5 Bus System: Bus system is a path for the transmission of signals. In the programmable controllers, it is responsible for the signal exchange between processor and input / output modules. The bus comprises of several signal lines i.e. wires and tracks. There are three buses in a PLC: Address bus, which enables the selection of a memory location or a module. Data bus, which carries the data from modules to processor and vice versa. Control bus, which transfers control and timing signals for the synchronization of the CPUs activities within the programmable controller. 3.1.6 Power supply: The power supply module generates the voltages required for the electronics modules of the PLC from the mains supply. Typically 1 phase, 230V AC supply is converted in to 24V DC supply by power supply module. It should be noted that CPU needs 24V DC input and the other voltages required by the PLC hardware such as 5V DC etc. is generated by CPU. 3.1.7 Additional Modules: -
In addition to the above listed modules, the other frequently used modules in a PLC system are Interface Module, Communication Processor Module and Function Module or Intelligent Periphery Module.
Power Supply
PLC
Output Module
signal. This internal memory of CPU is called as PII, meaning Process Image Input. The programmable controller operates cyclically meaning when complete program has been scanned, it starts again at the beginning of the program. Step 1: Bringing input signal status to the CPU I / O Bus
Field Signal
Input Module
CPU
PIQ
Once the field input status is brought into the internal memory of CPU i.e. PII, the execution of user program, statement by statement begins. Based on the user program the CPU performs logical and arithmetic operations on the data from PII. It also processes timers and counts as well as flag states based on the instruction written in the program. The program is generally written in structure logic (STL) at the side of operator. The results of the user program scan i.e. decisions are then stored in the internal memory of CPU. This internal memory is called Process Image Output or PIQ. Step 2: -processing of signals.
CPU
User Program Memory
CPU
Output Module Field Output Devices
PII
PIQ
Notice in this example we had to respond to 3 things: INPUT- It took a certain amount of time for the brain to notice the input signal from the eyes. EXECUTION- It took a certain amount of time to process the information received from the eyes. Consider the program to be: If the eyes see an ugly picture then output appropriate words to the mouth. OUTPUT- The mouth receives a signal from the brain and eventually spits (no pun intended) out the words "Gee, that's a really ugly picture!"
4.5 Selecting I/O module: 1. How much I/O is required to control process? 2. What type of I/O is required to control process (es)? 3. What is required voltage range for each I/O module? 4. What is back plane current requirement for each I/O module? 5. What are the noise and distance limitation for each I/O module? 6. What isolation is required for each I/O module?
PROGRAMMING OF PLC
The PLC like computer is software driven equipment. How the PLC should work or say control the machine or process is decided by the user through User Program . Depending upon the process control requirement the user prepares the program, meaning writes the instructions . These instructions are then stored in the User Memory or Program Memory of CPU in the form of machine code. The CPU sequentially reads these instructions and operates the control elements taking into consideration the input status and the program instructions. In this manner the PLC controls the process. The next information that one needs is about the Programming Language. One thing which I would like to tell you about Programming language of PLC is that every PLC manufacturing company uses its own language for example, the programming language used in the programming of SIEMENS make PLC is called Step-5 for SIMATIC S5 family PLC or Step-7 for SIMATIC S7 family of PLCs. With STEP-5 / STEP-7 language the user can communicate with SIEMENS make PLC, respectively SIMATIC S5 and SIMATIC S7-300 / 400. The STEP5 / STEP7 are considered to be the most user friendly, simple to understand and application oriented programming language. For programming we need a Programming Unit (PG). There are different types / models of programming units available for programming of PLC. It is also possible to use a general purpose PC as a programming unit by loading it with STEP5 / STEP7 software and using a converter / adapter.
The programming can be done either on line or offline: Off line programming means writing of instructions in a PG and not in the program / user memory of CPU. In on-line programming the programming unit is directly connected to the programming port of the CPU and then the instructions are directly written into the user memory of CPU. Initial keying-in of program is normally done in the off-line mode (i.e. programming unit is not connected to the programmable controller), and after checking and verifying, the program is transferred to CPU. After the commissioning the program is transferred to the EPROM memory module as a backup and the controller can now operate independent of the programming unit. One of the important features of STEP 5 / STEP 7 programming language is its flexibility. WE can write the user program in any one of the following forms: 1. Statement List (STL) 2. Control System Flowchart (CSF) or Function Block Diagram (FBD) 3. Ladder Diagram (LAD)
I 2.3 conveys that the operation is to be performed with the sign input indicated By with address 2.3 The complete statement / instruction in this case is: A I 2.3
&
Q 1.6
The symbols used are in accordance with DIN standard ref: 40 700/DIN. This method is preferred by those users who are familiar with the logic symbols / logical machine and process sequence.
Basically the individual formats i.e. STL or CSF / FBD or LAD can be converted into each of the other formats using the programmer i.e. program written in say LAD can be converted into CSF / FBD or STL etc. However there are some limitations and also certain care needs to be taken in programming if conversion is desired
Initially the tank is empty. Therefore, input 0000 is TRUE and input 0001 is also TRUE.
Scan 2-100
After 100 scans the oil level rises above the low level sensor and it becomes open. (i.e. FALSE)
Scan 101-1000 Notice that even when the low level sensor is false there is still a path of true logic from left to right. This is why we used an internal relay. Relay 1000 is latching the output (500) on. It will stay this way until there is no true logic path from left to right.(i.e. when 0001 becomes false) After 1000 scans the oil level rises above the high level sensor at it also becomes open (i.e. false)
1001
Scan 1002
Since there is no more true logic path, output 500 is no longer energized (true) and therefore the motor turns off. After 1050 scans the oil level falls below the high level sensor and it will become true again.
Scan 1050 Notice that even though the high level sensor became true there still is NO continuous true logic path and therefore coil 1000 remains false! After 2000 scans the oil level falls below the low level sensor and it will also become true again. At this point the logic will appear the same as SCAN 1 above and the logic will repeat as illustrated above.
PLC SOFTWARE
Since PLC is a Programmable device it means its program can modify. As we know a set of instruction is known as program. Each programmable device only recognized its instructions. Therefore a Package needed for PLC programming. This package (programming software comes with PLC. The software has many features i.e. for programming instruction palate, input/output module details inbuilt help etc.. There are three methods of writing program: 1. Ladder Logic 2. Sequential flow chart 3. Structured text
6.1 Ladder Logic: Program using a language that is reprehensive of relay logic. This language become very easy if: More familiars with ladder/relay logic than with programming language such as basic. Performing diagnostics. Programming discrete control. |------[ ]-----[/]--------( )-----| |----+--[ ]--+--- [/]----( L)----| +--[/]--+
|------[/]-----[/]--------( U )--|
6.2 Sequential flow Chart:It is useful to control and display the state of a sequential control process. In this language Logic is divided into steps and transition. A step Correspondence to a control task and a transition is Correspondence to a condition that must occur before the Programmable controller can perform the next control task. The displays of these steps and transition lets you see,what state the machine process is in at a given time via a flowchart form. SFCs are best for defining the order of events in a sequential process.
6.3 Structured text: It is programming method similar to BASIC Structured text is beneficial if: More familiar with programming languages such as BASIC than with ladder logic. Using complex mathematical algorithms. Using program construct that replete or loop. Creating custom data table monitoring screens.
PLC COMMUNICATION
PLC can communicate between: PLC to PLC. PLC is Programmable logic controller. PLC to HMI (MMI) HMI stand for Human Machine Interface MMI is Man Machine Interface PLC to Terminal (PC) PC is Personal computer PLC to RIO. RIO stands for remote Input output. PLCs CPU module has two types of communication ports one is serial communication port (RS232) and another is Parallel communication port. Each and every intelligent device, which is connected to PLC, has a unique node number. Every device connects on their assigned number. For Proper Communication Baud rate must properly specified. There are special types of communication cable, which are developed by different PLC Company. There is cable length limit, which is different for different cables. PLC (Node 0o) HMI (Node 2o) PLC to HMI
Node: - A junction point is termed as node from where active devices connected. RIO:-Remote Input Output is an adapter module which supports few Input output module. It resides in a remote area from which a communication cable comes to CPU processor (in case of SLC it comes to Adapter module.) All inputs and outputs devices situated in remote area connected to RIO I/O module. Adapter module has Input and output image allocation in memory. This information is sanded to PLC CPU module via communication cable. All design making process held in PLC CPU module according to pre-written program.
. .
Abbreviations: Red Arrow: - Outputs to RIO module Blue Arrow: - Inputs to RIO module Black Arrow: - power supply of field devices. Advantage of Remote Input Output: 1. Only one cable is pulled from remote unit to Resident PLC unit that is Communication Cable. 2. Less probability of breakdown. 3. Less probability to getting noisy signal. 4. Thermocouple, 4-20 mA signal are received to processor without any electrical interference or distortion. 5. Economical, as it reduces the cable length of remote devices to PLC. 6. RIO module can be placed in hazardous area such as furnace, Capacitor bank etc. From there to Local PLC chassis its information comes via communication cable.
A LEVEL APPLICATION
Now that we've seen how registers work, let's process a program like PLCs do to enhance our understanding of how the program gets scanned. Lets consider the following application: We are controlling lubricating oil being dispensed from a tank. This is possible by using two sensors. We put one near the bottom and one near the top, as shown in the picture below.
Here, we want the fill motor to pump lubricating oil into the tank until the high level sensor turns on. At that point we want to turn off the motor until the level falls below the low level sensor. Then we should turn on the fill motor and repeat the process. Here we have a need for 3 I/O (i.e. Inputs/Outputs). 2 are inputs (the sensors) and 1 is an output (the fill motor). Both of our inputs will be NC (normally closed) fiber-optic level sensors. When they are NOT immersed in liquid they will be ON. When they are immersed in liquid they will be OFF. We will give each input and output device an address. This lets the plc know where they are physically connected. The addresses are shown in the following tables: Inputs Low High Address 0000 0001 Output Motor Address 0500 Internal Utility Relay 1000
Below is what the ladder diagram will actually look like. Notice that we are using an internal utility relay in this example. You can use the contacts of these relays as many
times as required. Here they are used twice to simulate a relay with 2 sets of contacts. Remember, these relays DO NOT physically exist in the plc but rather they are bits in a register that you can use to SIMULATE a relay.
We should always remember that the most common reason for using PLCs in our applications is for replacing real-world relays. The internal utility relays make this action possible. It's impossible to indicate how many internal relays are included with each brand of plc. Some include 100's while other include 1000's while still others include 10's of 1000's! Typically, plc size (not physical size but rather I/O size) is the deciding factor. If we are using a micro-plc with a few I/O we don't need many internal relays. If however, we are using a large plc with 100's or 1000's of I/O we'll certainly need many more internal relays.
CONCLUSION
Originally PLCs were conceived as a replacement for hard-wired logic control. However with technological development the PLCs very rapidly evolved far beyond that and are used today in a diverse range of industrial and process control application. Under real time conditions they can control production sequences, handle data communication task and enable convenient monitoring and controlled manipulation of process. Increased intelligence combined with ease of programming and compact design has made PLCs become indispensable mainstay of todays decentralized automation system. Today the demands from industry / market are to consistently high quality of the final products, minimization of costs, an extensive communication system to allow exchange of information both between various automation systems and from man to machine and vice versa. PLCs meet all these requirements and hence, today the PLC constitutes the basic building block of an Automation System. I would also like to point out that in the near future company can prefer to use fuzzy logic controller because it is much easier to use as other controllers because it is based on linguistic details and will be much more faster. Finally I would like to say that PLCs have been a boon for the process industry like HINDALCO.
REFERENCES
1. Jack, Hugh. , Automating Manufacturing Systems with PLCs,5th edition, Boston ; Free Software Foundation,2002. 2. Ganesh, M.,Introduction to Fuzzy Sets and Fuzzy Logic,1 st edition, New Delhi; Prentice-Hall of India Private Limited, 2006, p.169-179. 3. http://www.hindalco.com 4. http://www.plcs.net/ 5. Material provided by staff.
GLOSSARY
A Address: - a code that specifies a location in the computers memory. Actuator: -a device when activated will result in a mechanical motion Algorithm: -a software procedure to solve a particular problem. Analog signal: -a signal that has continuous values, typically voltage. B BASIC: -Beginners all purpose symbolic instruction code (a high level language used for programming. Baud: -Maximum no. Of bits that can be transmitted through a serial line in one second C Contactor: - A high current relay. Communication: - transfer of data between two units such as computer, humans. CPU: - Main computer element that examines machine code instructions and executes them. D DC: - Current that flows in one direction (the alternative is AC). F Flag: - A single binary bit that represent event has/has not happened. H HMI: -Human Machine Interface. I Instruction set: - list of all commands that is available in a programming system.
Input/output: - A term that describes something is going in or out of computer. L Ladder diagram: - A form of circuit diagram normally used for electrical control systems. Ladder Logic: - A programming language for PLC that has been made to look like relay diagrams from the preceding relay logic controls. Limit Switch: - A mechanical switch actuated by motion in the process. M MMI: - Man Machine Interface (a user interface terminal). Module: - A part of a larger system that can be interchanged with others. O Open System: - computer architecture designed to encourage interconnection between various vendors hardware and software. Opcode: - A single Computer Instruction. Operand: - An Operation has an Argument. P Parallel communication: - bits are passed in parallel conductors and hence increasing the speed dramatically. R Racks: -A housing for holding electronic modules/cards. Register: - A high-speed storage area that can store a word for faster calculations. Relay: - An electrical Switch that comes in many different forms. The switch is activated by magnetic coils that cause the switch to open or close. Respond time: - The time required by system to respond to a directed change.
RS232: - A serial communication standard for low speed voltage based signals, that is very common on most computers. But it has a low noise immunity that suggests other standards in harsh environments. RS-422: - a current loop based serial communication that works well in noisy environment. RS-485: - Uses two current loop for serial communications.
S Solenoid: - An actuator that uses a magnetic coil. When energized it will cause linear motion. T Transducer: - A device that will convert energy from one form to other. TRAIC: - A semiconductor switch suited to AC Power. V Valve: - A system component for opening and closing mass/energy flow paths.