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PREFACE
As a part of the curriculum prescribed for Bachelors Degree of Engineering by Rajasthan Technical University, Kota. A total of 40 days practical training has to be taken after third year completion. Thus being a student of engineering I have completed my training at VIDEOCON INDUSTRIES LIMITED, SHAHJAHANPUR. Practical training is one of the major tasks for any professional course. The real place where a professional person faces and tackles the problems was able to get familiar to various processes in the industry. I was given a project on PLC in the duration of 40 days.
ACKNOWLEDGEMENT
I am highly thankful to Mr. Rajesh Gupta and Mr. Yogesh Gupta, for providing me the opportunity to work on the current project i.e."PLC" with their prestigious organization to take my training as per the curriculum of the Bachelors Degree of Engineering, as prescribed by Rajasthan Technical University, Kota. I am deeply indebted to Mr. Yogesh Gupta for assigning the project, and also grateful to Mr. Divaker for sharing his views and giving total insight into the minor details of the project as well as that of the organization and grateful to him for helping me in preparing my Training Report. The help rendered by Ms. Sumita Dutt from time to time is also thankfully acknowledged. The keen Interest shown by Mr. Yogesh Gupta during the course of the final project and these investigations is creditable.
Contents
Introduction of the Company Name of shops Process of plant Function of Maintenance Department Project Report PLC Series S5 S7-200 S7-300
PLANT SHOP
Press shop Paint shop Vacuum forming shop Foaming area Pre-Assembly shop Final Assembly shop
To liaison & co-ordinate with the functionaries of government i.e. Rajasthan State Electricity Board, RIICO, Pollution Control Board & other department.
MAINTAINANCE DEPARTMENT:
1.0
1.1
RESPONSIBILITY:
Functional Head (Plant Engg) is overall responsible for proper functioning of all the machines and equipment of the plant. Respective Incharge (Maintenance) for the activities assists him. In charge (Mechanical Maintenance), in charge (Electrical Maintenance) and Incharge (Utilities) are responsible for maintenance related to their area of activities.
1.2 1.3
Shift In charge (maintenance) is responsible for maintenance during any particular shift. Individual responsibilities for specific activities are given below in description.
1.4
2.0
S. No. 2.1 2.1.1 2.1.2
DESCRIPTION:
Activity
Identify the key machines / equipments, which affect quality and to be covered under maintenance Maintain a List of the identified machines / equipments.
2.1.4 2.1.5
Based on the above, prepare Annual Maintenance Schedule for electrical, mechanical and utilities.
Ensure recording of various checks parameters of DG set, air compressors, thermopac, and RO plant in logbooks. The control parameters for each operation are as per specification sheets.
2.1.7
Periodically examine Maintenance Schedule and inform the concerned Maintenance Crew for carrying out Preventive Maintenance activities as per relevant checklists. Get Checklist from respective In charge (Maintenance) and carry out all activities as given in checklist. Inform the activities carried out including earlier slippage if any, to respective In charge (Maintenance) who updates the Maintenance Schedule.
2.1.8 2.1.9
2.1.10
If any of the maintenance activities are not carried out as per schedule / checklist, enter the details in maintenance log book/ utilities logbook for inclusion next time. scheduling the maintenance activities at next available opportunity. Monitor them for accomplishment.
2.1.10.1 Review the maintenance log book and make necessary arrangement for re-
2.1.11
In case any major replacement / repairs are carried out, enter the details in Machine History Card Change the preventive maintenance frequency and inform respective In charge (Maintenance) accordingly. Predictive Maintenance Take a round of the plant daily in the General Shift and examine the condition of machines / Equipments. Inform the abnormality observed if any too concerned Section In charge and request for sparing the machine for needful Activity In case the machine can not be spared due to urgency of production but the same can work, record the observations in maintenance log book/utilities log book. Periodically examine the maintenance/utilities log book and get it corrected on next available opportunity. Note: Normally, such abnormalities are removed on coming Sundays.
2.1.11.1 Review the machine history card once in every six months. If required,
2.3
In order to attend the breakdowns in most effective manner & in the shortest possible time the following procedure is adopted.
2.3.1 2.3.2
On receipt of complaint (by verbal / written) from user department. Depute technician for carrying out necessary repairs Identify the nature of defects & arrange repair.
In case of problems beyond control consult shift in charge / Engineer & arrange repair / rectification as directed. When ever required, procure materials from stores by raising demand & issue slip after getting authorization from shift in charge. In case of low / no stock raise Purchase Requisition whenever required. In case the machinery / equipment is to be sent outside the factory for repairs put up the requisition for out going material after authorization from FH (PE). After completion of repairs and satisfactory operation enter details in maintenance / utilities log book. Activity Interact with maintenance purchase in charge & maintenance store in charge to ensure the availability of minimum stock as required. If required follow step 2.1.11 & 2.1.11.1 Reports Decide Maintenance Objectives during the management review meetings based on the current breakdown trends. Compile machine Breakdown time for the month of all area of activities including Breakdown Analysis (i.e. causes). Discuss the Machine Breakdown Trend Chart in Management Review Meetings and take suitable corrective measures to meet as well as improve upon the laid down objectives. Submit Monthly Utility Report to management about generation and consumption of energy and fuels. Submit maintenance overtime report to the management about
2.3.7
S. No. 2.3.9
2.4.3
2.4.4 2.4.5
manpower utilization.
PROJECT REPORT
Scope of Study
Study of PLC System at Videocon, Various Frequency Drives use and their programming, Power Supply, Communication and Networking of PLC. Following PLC Systems study in respect to their Operating Software, Hardware, and Programming of Small PLC Logic and necessary modification in existing Programs along with trouble shooting in PLC System Siemens PLC with S5 Series
Along with PLC system study of Various Frequency Drive i.e. Micro Master Inverters with following scope of Study Introduction of Frequency Drives Hardware Programming of Frequency drives as per requirement Function and Operation of Frequency drives Application
Type of Frequency of Frequency Drives Siemens Micro Master from 0.5 HP to 3.0 HP Power Supply
PLC refers to programmable logic control as the name suggests it is a computer used to control the different operations of a machine to which it has been connected. The different operations to be performed are judged in sequence by the PLC as per the program in the PLC PLC generally consists of a CPU, input and output ports. A CPU is of 2 type -: With an i/o device Without an i/o device Different hardware is connected to the PLC so as to handle different operations of the machines to has been connected.
PLC is used -: 1) To control different functions done by the machine 2) To provide protection to the people working manually on the machine and to the machine i some power failure or some cases of short circuit also. 3) To operate the machine automatically.
A program is fed to the PLC to make machines operate as per the requirement for the different ope the machines.
1. SEIMENS 2. OMRON 3. ALLEN BRADLEY PLC is manufactured by the SEIMENS in 2 version they are -: S5 S7 Further S7 has 2 versions -: 1. 200 (Micro Series) 2. 300 (Modular Series) Depending on the number of the input modules connected to the PLC The languages been used LAD-ladder Cascade Statement Function CSF STL statement line We have interfacing of the plc to the pc or vice versa through different modes TTY-text to text interface (interface between single pc to single plc) PPI- point to point interface (connections of different pc to a number of plc)
MPI-multiple point interface (connection of number of plc to more than one plc)
Problem
During the transfer of Foamed cabinet fixture from foaming station to inside carriage Insider carriage should be in backward position. But sometimes when this carriage is at forward position and because of Foam or otherwise Limit Switch might got stuck-up in backward position, It will give false input to PLC and both Inputs of Carriage forward & Backward will be available to PLC. This causes fixture transfer without carriage and causes damage to cylinders and major Accident occurs
The inputs and the outputs are the system control points: the input monitors the signals from the field devices (such as sensors and switches), and the outputs control pumps, motors, or other devices in your process. The communication port allows you to connect the CPU to a programming device or to other devices. Status lights are been provided to provide visual information about the CPU mode (RUN or STOP), the current state of the local I/O, and whether a system fault has been detected. The S7 Micro Series programming software offers powerful programming and debugging tools which make you more effective and this means cost savings. We use the programming in the same manner as the Windows applications User programs are written using simply mouse clicks, tool bars, or simply drag & drop operations .It have the following properties: -
4 or 6 independent hardware counters at the rate of 30 kHz each for interfacing to incremental encoders or high-speed pulse trains. 4 independent interrupt input with 0.2ms input filter times to adjust reaction times for maximum process response. 2 high speed pulse outputs at the rate of 20khz each either pulse width modulation or pulse train output , e.g. for control of stepper motor , drives or temperature . High-speed analog inputs signal conversion with 25micro seconds, 12 bit resolution. Real time clock. 2 timed interrupts (adjustable from 1ms in intervals of 1 ms) for precise control of processes that change over time.
EEPROM CARTRIDGE
A small optional EEPROM cartridge saves significant time and money. We can use it easily copy, update or replace your applications program on your S7-200 CPU. And if required, one can mail a program rapidly and at a low cost, using the cartridge. Simply turn off the power and the user program is updated in a flash.
BATTERY CARTRIDGE
To guarantee that applications data are never lost , the optional battery module permits long term backup for typically 200 days beyond the internal backup of 5 days .
ANALOG POTENTIOMETERS
With the S7 200s analog potentiometers we can optimize our process by means of a screwdriver. We can set memory values, timer values, counter presets or other variables without
Constant
Task 1
Tasks for a sample mixing tank Application
To write a program to control the filling operation, monitoring tank level, and control mixing and heating cycle of the mixing tank shown. The following tasks describe the process: Step1: Fill the tank with1 ingredient 1 Step2: Fill the tank with ingredient 2 Step3: Monitor the tank level for closure of the high-level switch
Step4: Maintain the Pump-status if the start switch opens Step5: Start the mix-and-heat cycle Step6: Turn on the mixer motor and steam valve Step7: Drain the mixing tank Step8: Count each cycle
Task 2
Task to make a circuit to on the motor by Star connection and after 100 sacs by Delta connection
To write a program to on the motor by Star connection and then by Delta connection after a period of 100 sec. The following steps can explain the program: Step1: To start the motor press on push button. This on Push button will give starting command of motor to PLC. Step2: Immediately after On Command to motor Main Contactor and Star Contactor of motor will be in switch on mode and motor will start in star connection. Star Connection
Step3: With the operation of star contactor one timer will start for 6 seconds and after completion of its time PLC logic will change the connection of motor from star connection to Delta connection. This complete sequence requires switching off of star connector and switching on the delta contactor without affecting the status of main contactor. Delta Connection Step4: To switch off the motor press Stop Push Button that will stop both main & Delta contactor to stop the motor.
Procedure: The circuit setup was made and the program was downloaded on the PLC by using a PC/PPI cable and developing communication with the Personal Computer. Thus the online status of the program was checked. In beginning there was a problem related to the timer .The timer was completing its cycle and then refreshing itself without cutting the supply of Star connection, thus the delta connection was not getting the supply. To put the connection in the switch on mode the timer was modified to T37 and the timer value was given as 100.Thus the problem was solved and the circuit was completed.
We have to connect a cable between our PLC and the personal computer on which we are running STEP 7-Micro/WIN 32. For simple PC/PPI connections, we have to set the dipswitches to 9600 baud, DCE, 11-bit. If we are using a modem or communications card, consult the installation instructions that came with the hardware. If we are using a simple PC/PPI connection, we can accept the default communications protocol that is offered in the "Setting the PG/PC Interface" dialog box when we install STEP 7-Micro/WIN 32. Otherwise, select a different communications protocol and verify the parameters (station address, baud rate, etc.) for our personal computer from the "Setting the PG/PC Interface " dialog box.
INVERTER(Frequency drive)
Inverter is a frequency drive used to invert the A.C. to D.C. and control the rpm of AC motors by variable frequency. The drive converts the phase from single phase to three phase if the power supplied is in single phase. These inverters are microprocessor controlled A special pulse width modulation with selectable pulse frequency permits extremely quiet motor operation. Microprocessor is available for reliable and flexible control. Remote control capability is also used to control inverters. It has a built in non-volatile memory for storing parameter settings. Output frequency can be controlled by one of the five methods -: Digital frequency setpoint Analogue setpoint Potentiometer Fixed frequency Remote data transmission The inverter has a built in dc injection brake which stops the motor by applying a DC current, this causes heat to be generated in the motor rather than the inverter and holds the shaft stationary until the end of the braking period. Braking is effective for the period of time set. But the frequent use of long periods of DC injection braking can cause the motor to overheat. Automatic load compensation is done by flux current control. The Power supply is supplied in single phase or in three phases and has an output always in three phases, so a 4-core wire is used for connection. Following are the specifications of the inverter -: Input frequency 47 Hz to 63 Hz Power factor - >=0.7 Output frequency 0 Hz to 650 Hz Resolution 0.1 Overload capacity 150% for 60 s, related to nominal current Protection against inverter overtemperature Motor overtemperature Overvoltage and undervoltage
Additional protection Against short circuit and earth/ground faults pullout protection against running with no load. Regulation and control FCC (flux current control) voltage /frequency curve Ramp times-0-650s Invert efficiency 97% Operating temperature 0 c to +40c Parameters can be changed and set using the membrane-type buttons to adjust the desired properties -: ParameterP000 Its function is to operate the display. This displays the output selected in P001 .In the event of a failure the relevant error message is displayed .In the event of a warning the display flashes .If output frequency has been selected (P001=0) the display alters between the selected frequency and the actual frequency. P001 Its function is to display selection .0-7 Numbers are used for display selection 0-output frequency 1-speed at which inverter is set 2- Motor current 3- DC-link voltage 4- Motor torque 5- Motor rpm 6- Use status 7- Closed loop display mode
P002 Ramp up time is the function done by this parameter, which is the time taken by the motor to reach the maximum frequency from the standstill condition, Its range is from 0-650 sec. P003 Ramp down time, it is the time taken to decelerate from maximum speed to minimum standstill position. P004 P005 Its function is to smooth the acceleration /deceleration of the motor. Digital frequency set point 0-650.00
P006 Frequency set point type selection 0-2 0- digital 1- 1-analogue 2- fixed frequency or motor potentiometer P007 Enable /disable front panel buttons 0-1 0-run, jog and reverse are disabled 1-front panel buttons can be selected P009 Parameter protection setting 0-3 0- only parameters from P001 P009 can be read / set 1- all the parameters can be read and P001-P009 can be set 2- all the parameters can be read /set but P009 is automatically set to zero when power is removed 3- all can be read/set P010 Display scaling
P011 Frequency set point memory 0-1 0-disable 1-enable after switch off
P016 Start on the fly 0-4 Allows the inverter to start on to a spinning motor, to avoid overcurrent trip. P017 Smoothing type 1-2 1- continuous smoothing 2- discontinuous smoothing P018 Automatic restart after fault P021 Minimum analogue frequency 0-650 P022 Maximum analogue frequency 0-650 P023 P024 P025 P031 Analogue input type Analogue setpoint addition Analogue output Jog frequency right (Hz)
P032
P033 P034 P041 P042 P043 P044 P045 P046 P047 P048 P049 P050 P051 P052 P053 P054 P055 P061 P062
Jog ramp up time Jog ramp down time 1st fixed frequency 2nd fixed frequency 3rd fixed frequency 4th fixed frequency Inversion fixed set points for fixed frequencies 5th fixed frequency 6th fixed frequency 7th fixed frequency 8th fixed frequency Inversion fixed set points for fixed frequencies Selection control function, DIN1 Selection control function, DIN2 Selection control frequency, DIN3 Selection control function, DIN4 Selection control function, DIN5 Selection relay output RL1 Selection relay output RL2
P063
P064 P065 P070 P071 P072 P073 P074 P075 P076 P077 P078 P079 P081 P082 P083 P084 P085 P086 P087 P088
External brake stopping time Current threshold for relay Braking resistor duty cycle Slip compensation Slip limit DC injection braking Motor derating curve as temperature protection Braking resistance Pulse frequency Control mode Continuous boost Starting boost Nominal frequency for motor Nominal speed for motor Nominal current for motor (A) Nominal voltage for motor (V) Nominal power for motor (kW) Motor current limit Motor PTC enable Automatic calibration
P089
Stator resistance
P099 P092 P093 P094 P095 P101 P111 P121 P122 P123 P124 P131 P132 P133 P134 P135 P201 P201 P203
Slave address Baud rate Time out Serial link nominal system setpoint USS compatibility Operation for Europe or USA Inverter power rating (kW/hp) Enable /disable RUN button Enable/disable FORWARD/REVERSE button Enable /disable JOG button Enable /disable Frequency setpoint Motor current Motor torque DC link voltage Motor RPM Closed loop mode Proportional gain Integral gain
P211 P212 P720 P721 P722 P727 P724 P910 P922 P923 P930 P931 P944 P971
0% set point 100% set point Minimum frequency mode Special input /output functions Analogue input voltage Analogue output current State of digital inputs Relay output control Local/Remote mode Software version Equipment system number Most recent fault code Most recent warning type Reset to factory default settings EEPROM storage control
Power Supply
Power Supplies are the devices which converts AC to DC. It gives a stabilized output power. The power supply has longer lifetime for connected loads, less heat dissipation, more compact construction & more functions like switching Mode. These are Switched mode power supply which range from 24V/2A to 24 V/40A(Single phase /3 phase). With an extremely high efficiency of around 90%, they reduce energy wastage . The power supplies in switching mode are safe as they trip the circuit during high voltage ect. The higher efficiency results in low dissipation heat and results in lower current operating costs without losses in power. The constant supply from the switched mode power supply protects the module against overvoltage and undervoltage in the extended allowable range of variations of the input voltage.
CONCLUSION
As per the curriculum prescribed by the Rajasthan Technical University, Kota. Bachelors Degree in Engineering student has to complete a training of 40 days after the III year completion. Thus I have completed my training of 40 days after III year at VIDEOCON INDUSTRIES LIMITED, SHAHAJAHANPUR. I was given the training in the maintenance department of the company ,where I was given a project on PLC and a hardware study on inverter and Power supply .