Abhinav Traiing Report

8/6/2019 Abhinav Traiing Report

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CHAPTER 1

INTRODUCTION TO AUTOMATION

The basic mean of automation is to become a system automatic , mean it complete all thegiven task automatically, the definition of the automation is to anlyze and control all the

process parameters in the plant or in a machine with the help of automatic device is calledthe automation.

When a machine or a system is controlled by the another system or machine , then itiscalled an automatic system . in this type of system we can use the feedback controltechnology for the accurate operation of our system.

In an automation system , all the components of the system works automatically , weonly require the starting and stopping of the system remaining system works itself.

Benefits of an automatic system

We use the automatic sytem in these days and it is increased regularly because it has several benefits. Some of the benefits are as follows :-

1. Increasing productivityWhen a system change in an automatic system, its productivity is increased becausethere are no losses like tension, fatigue, laziness which are associated with manualsystem, so overall productivity increases.

2 . Increase qualityWhen we change a system in a automatic system, the quality of our product isincreased because there is no chance of the error due to human beings , and all system

works as they are instructed by the operator.3 . Reduce overall production cost

When we change a system in an automatic system then overall production cost of thesystem is reduced because the manpower is reduced and rate of manufacturing isincreased.

4 . Increased safety at workplaceThe manpower required is reduced and all the work is done automatically by themachine, so the safety of the humankind is increased ay work-place and the chance of accidents are also reduced.

5 . F lexibility to expand the system

In an automatic system our system being more flexible because now we have onlychange some function of automation devices to change our requirement and our system works being changed, so the flexibility of our system is increased byautomation.


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AUTOMATION POSSIBILITY:

1. There is a desire to exercise superior control on process parameters. 2 . There is a desire to significantly reduce the human interaction. 3 . There is a desire to enhance the process efficiency. 4 . There is a benefit that prevention is better than cure. 5 . R epetitive and monotonous jobs is involved and each stage of production needs

careful attention of operators to ensure good quality of final products. 6. Hazardous condition of operation can exist in plant.


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Automation history: -

Following diagram describes the technological advancements in the field of automation.

F ig 1.1 : technological advancement in automation

P.L.C

Electronic control using logic gates

Hard wire logic control

Pneumatic control

Manual control


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Manual control:

All the action related to process control and taken by the operators. Simply

manual controls is defined where all the final control element are adjusted

manually to control process to meet the manufacturing processrequirements.

Drawbacks of manual control:-1. Due to human interference errors are introduced in control which

largely effect the quality to final product.

2. The Production , safety , energy consumption and usage of rawmaterial increase due to inaccuracy in manual control.

3. Due to above two effect difference in coast unvalued inmanufacturing process and final product coast is largely reduced

that will be direct loss for the manufacturer.

Pneumatic control:-1. Pneumatic system works on air pressure, feedback signals and set

paints and controllers output all are in the term of air pressure.

2. Action were controlled by a simple manipulated of pneumatic values,which is turn were controlled by relay and switches.

Advantage over manual control:-

1. R eplaced bulky manual valves by pneumatic valves no need of involving huge man power to operate these valves.

2. Overall better control as compare formal system.

Drawbacks:

1. Bulky and complex networks of pneumatic pipes.2. Transmission of pneumatic signal at long distance is difficult.3. Involved lot of networks to implement of new control logic.4. System subjected to air leakage problem.5. Huge power required to create air pressure.

6. Longer project time.


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Hardwired logic control:-

The contractor and relay together with hardwire timers and counters were used inachieving there desired level of automation.

Advantage over pneumatic control:

1. R eplaced bulky pneumatic control panel.2. Signal transmission for long distance is possible without droop.

3. Pneumatic is now limited to final control element only.4. Air consumption reduced.5. R esponse of electrical system is high and fast so accuracy of control ishigh.

Drawbacks:

1. Bulky and complex networks of electrical network.2. Involves lot of network to implement control logic.3. Addition in logic is very difficult.

Electrical control using logic gates: -

1. The logic gates stated replacing the relays and auxiliary contactors inthe control circuits.

2. The hardware timers and counters were replaced by electric timers.Advantage of electrical system:

1. Electric equaling is less space as compared to other system.2. Timers and counter are more accurate.3. Mathematical calculation are possible.4. Less maintenance and greater reliability.

Drawbacks:

1.

Change is control logic not possible.2. Skill professional are required to trouble shoot control logic.3. Components are not interchangeable if application are different.


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Chapter 2 INDUSTRIAL AUTOMATION

Automation is the use of control systems and information technologies reducing the need for

human intervention. In the scope of industrialization, automation is a step beyond

mechanization. Whereas mechanization provided human operators with machinery to assist

them with the muscular requirements of work, automation greatly reduces the need for human

sensory and mental requirements as well. Automation plays an increasingly important role in

the world economy and in daily experience .

2 .1 AUTOMATION TOOLS:

Engineers now can have numerical control over automated devices. The result has been a

rapidly expanding range of applications and human activities. Computer-aided technologiesnow serve the basis for mathematical and organizational tools used to create complex

systems. Notable examples include Computer-aided design (C AD software) and Computer-

aided manufacturing (C AM software). The improved the design, analysis, and manufacture of

products has been beneficial for industry[1].

Information technology, together with industrial machinery and processes, can assist in the

design, implementation, and monitoring of control systems. One example of an industrial

control system is a programmable logic controller ( PLC). PLCs are specialized hardenedcomputers which are frequently used to synchronize the flow of inputs from (physical)

sensors and events with the flow of outputs to actuators and events[3].

Human-machine interfaces ( HMI) or computer human interfaces (C HI), formerly known as

man-machine interfaces, are usually employed to communicate with PLCs and other

computers. Service personnel who monitor and control through HMIs can be called by

different names. In industrial process and manufacturing environments, they are called

operators or something similar. In boiler houses and central utilities departments they are

called stationary engineers[3].

Different types of automation tools exist:

y A NN - Artificial neural network

y DCS - Distributed Control System


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y HMI - Human Machine Interface

y SCADA - Supervisory Control and Data Acquisition

y PLC - Programmable Logic Controller

y PA C - Programmable automation controller

y Instrumentationy Motion control

y R obotics

2 .2 IMPACT:

Automation has had a notable impact in a wide range of highly visible industries beyond

manufacturing. Once-ubiquitous telephone operators have been replaced largely by

automated telephone switchboards and answering machines. Medical processes such as

primary screening in electrocardiography or radiography and laboratory analysis of human

genes, sera, cells, and tissues are carried out at much greater speed and accuracy by

automated systems. Automated teller machine has reduced the need for bank visits to obtain

cash and carry out transactions. In general, automation has been responsible for the shift in

the world economy from agrarian to industrial in the 19th century and from industrial to

services in the 20th century .

2 .3 APPLICATIONS O F AUTOMATION:

(a) Automated Video surveillance:

The Defense Advanced R esearch Projects Agency (DARPA ) started the research and

development of automated Visual surveillance and Monitoring (VS AM) program 1997-99

and airborne Video Surveillance ( AVS) program 1998-2002. Currently there is a major effort

underway in the vision community to develop a fully automated tracking surveillance system.

Automated video surveillance monitors people and vehicle in real time within a busy

environment. Existing automated surveillance systems are based on the environment they are primarily designed to observe, i.e., indoor, outdoor or airborne, the amount of sensors that the

automated system can handle and the mobility of sensor, i.e., stationary camera vs. mobile

camera. The purpose of a surveillance system is to record properties and trajectories of

objects in a given area generate warnings or notify designated authority in case of occurrence

of particular events[3] .


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(d) Home Automation

Home automation (also called demotic) designates an emerging practice of increased

automation of household appliances and features in residential dwellings, particularly through

electronic means that allow for things impracticable, overly expensive or simply not possiblein recent past decades .


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CHAPTER 3

PLC ARCHITECTURE

PLCs contain three basic sections:

1.

Central processing unit (C PU).2. Memory: E PR OM, RAM, and so on.

3. Input/output section for communication with peripherals ( ADC, DAC).

F ig 3 .1 PLC structure

As shown in fig 3.1 ,a PLC is basically a box with a number of inputs from, and a number of

outputs to, the outside world. It can make decisions, store data, do timing cycles, do simple

arithmetic, convert codes, and so on. The basic difference between this black box and a

hardware logic system using IC chips or a relay controlled system, is that specific coded

messages are stored in areas called program memory, which are PR OM or R OM and RA M

chips. It is, however, much easier to change a program when a different process is requiredthan to rewire the control system. For example, it may take electricians a couple of weeks to

require a pipe mill, whereas a programmer will spend only a fraction of this time to

reprogram a PLC since no wires will have to be changed. In addition, various recipes can be

stored in memory and accessed when required, making the program extremely flexible.


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The system operates through interaction with the processor and program memory. When the

power to the system is turned on, the processor reads the first instruction stored in memory

and acts on this instruction. When completed, it goes back to the memory for the next

instruction, and so on until task is complete. This operation is called the fetch-execute cycle.

The processor communicates with the outside world via input and output modules .

3.1 THE PARTS O F A PROGRAMMABLE CONTROLLER:

Programmable logic controllers ( PLC) can be considered to have three parts:

3 .1.1 Input/output Section

The I/O section contains input modules and output modules. Functionally, the input modulesare equivalent to the signal converters (i.e. Analog to Digital or high power to low power).

All modern PLC input modules use optical devices to accomplish electrically isolatedcoupling between the input circuit and the processor electronics.

F ig3 .2 Input Output Assembly

Fig 3.2 shows input output assembly. Inputs carry signals from the process into the controller.Outputs are the devices that the PLC uses to send changes out to the world.


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into R UN mode, which causes the C PU to start executing the program from beginning to end

repeatedly.

(e) The complete scan cycle

As long as the PLC is left in the R UN mode, the processor executes the user program over and over again. Figure depicts the entire repetitive series of events. Beginning at the top of

the circle representing the scan cycle, the first operation is the input scan. During the input

scan, the current status of every input module is stored in the input image table, bringing it up

to date[6].

Following the input scan, the processor enters its user program execution. Sometimes called

program scan. The program executes with reference to input and output image tables and

updates output image table. Throughout the user program execution, the processor

continuously keeps its output image table up to date, as stated earlier. However, the output

modules themselves are not kept continuously up to date. Instead, the entire output image

table is transferred to the output module during the output scan following the program

execution.

(f) Data Memory:

A PLC is a computer, after all. Therefore, it can perform arithmetic, numeric comparisons,

counting, etc. Naturally the numbers and data can change from one scan cycle to the next.

Therefore the PLC must have a section of its memory set aside for keeping track of variable

data, or numbers, that are involved with the user program. This section of memory we will

call data memory.

When the C PU is executing an instruction for which a certain data value must be known, that

data value is brought in from data memory. When the C PU executes an instruction that

provides a numerical result, that result is put out into data memory. Thus, C PU can read from

or write to the data memory. Understand that this relationship is different from the

relationship between the C PU and the user program memory. When the user program is

executing, the C PU can only reads from the user program memory, never write to it.

(g) Operating System of PLC:

The function of the operating system is to present the user with the equivalent of an extended

machine or virtual machine that is easier to program than the underlying hardware. Due to

this operating system, PLC is very easy to program. It can be programmed using electrical


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schemes with familiar relay symbols so that a plant electrician can easily access the PLC.

Even though he does not know the assembly language or even if he may not have any

familiarity with computers and electronics, he will be able to program the PLC.

The function of PLC Operating system is:

1. Loads the user program from programming device to program memory.2. To read status of input devices.

3. To execute user program.

4. To form and update input image table.

5. As per the status of output image table controls the output devices.

6. To provide user-friendly functions.

This O.S. makes supervision over entire system, so O.S. programs are said to running in

supervisory mode. When the user completely enters his program in user memory, he transfers

control from PR OGRAM mode to R UN mode. In R UN mode the control of the whole

system is transferred to operating system. Now operating system takes care of the whole

system such that the whole system becomes automatic and appears as magic to users.


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CHAPTER 4

SYSTEM OVERVIEW O F PLC

A PLC contains following important parts

4 .1 CPU

It usually contains (but sometimes it is external and separate) an Arithmatic Logic

Unit. This is the part that performs operations such as adding, subtracting ,multiplying

,dividing and comparing.

As shown in fig 4.1,the buffer act as switches that isolate the lines on either side if required.

A , B , C are latches that passes the data from one side to the other when told to do so.

The busses are connected to memory chips, which stores digital numbers in location. The

number is the data while the location is the address. Data can be sent to or brought from

memory locations by either writing it or reading. R and W are signal lines that make C PU

read or write.

A R egister is a temporary memory location where data is put to be manipluted and then taken

away.

The reset line when activated resets the program counter to zero

The operations are carried outto a set of instruction ( the program) and these are decoded in

the I D(instruction decoder).

F ig 4 .1 Internal structure of CPU


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4 .2 INPUT MODULE

The input module connects the input terminals to the rest of the system. Each terminal isusually electrically isolated from internal electronics by O PTO isolators. This is a way of

passing on the status of the input (on or off) by use of LE D and PH OTOT RA NSISTO R S .

They have the advantage of reducing the effects of superiors pulses generated fromelectromagnetic sources. It is also a safety feature to prevent live voltages appearing on theinput lines in the event of a fault.

This part of system is on separate board connected to processor via cable. It allows the

processor to communicate with the outside world. It is also called Data Acquisition System

(DAS).

This part of system provides 4 digital inputs consisting of 2 dc and 2 ac, 4 digital outputs

consisting of 2 dc and 2 ac each. It also provides 8 analog inputs with following ranges:

1. 5v to +5v (one channel).

2. 0v to 10v (one channel).

3. 4mA to 20m A (one channel).

4. 0v to 5v (five channel).


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4 .3 OUTPUT MODULE

The output module contains switches activated by the C PU in order to connect two terminalsand so allow current to flow in external circuit. This will activate devices such as pneumaticsolenoid valves, hydraulic solenoid valves, motors, pipeline valves, heating element, e.t.c

Care must be taken not to overload the contacts. The switch may be a transistor or a relay.Fig 4.3 shows a typical output arrangement. The terminals are numbered and these numbersare used in program.

F ig 4 .3 Output module of plc

4 .4 STYLES

The main styles are UNIT AR Y, MO DULAR and RACK mounting.

As shown in fig 4.4, Unitary PLC contains every feature of a basic system in one box. Theyare attached to the machine being controlled.

F ig 4 .4 Unitary PLCS


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Modular style uses a range of modules that slot together to build up a system. The basicmodules are the power supply, the main module containing the C PU, the input module andthe output module. Other modules such as A/D converters may be added. The mainadvantage is that the number of input and output terminals can be expanded to cope withchanges to the hardware system.

Modular PLCS may be designed to be fixed direct to a back panel. Usually they are arrangedon a rack or rail or mounted inside a large cabinet for protection and security as in fig4.5.

F ig 4 .5 Modular and rack mounting PLCS

RACK mounting is a similar concept to the modular design but the modules are on standardcards that slot into a standard rack inside a cabinet. These are flexible and allow expansion of the system.


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4 .5 VOLTAGE SENSING RELAYS

They are used with analog devices that produce a voltage representing the variable. The unitis adjusted to trip a relay when a certain point is reached. Typically 24 V is applied to thePLC input. Another example is a level measuring device that produces a voltage proportional

to level and when the level reaches a certain depth, the voltage sensing relay trips andactivates the PLC input.

4 .6 INPUT VOLTAGES

Typical input voltages are 12 V and 24 V but sometimes they can be as low as 5 V or as highas 110V or 240 V. They may accept d.c or a.c . No two PCs are the same so you must takecare to check the input ratings.

4 .7 OUTPUT DEVICES

Output devices are switched on by the PLC.These can be anything electrical such as

following:

1. D C motor ( to start a conveyor belt).2 . A C motor ( to start a pump).3 . Lights ( traffic lights)4 . Alarms( fire alarm or oil level alarm)

Typical switching voltages are 12 V , 24 V, 110 V , and 240 V. In many cases , the PLCcannot switch the device directly because of hgh voltages or current needed. In this case

power switching relays or transistors are used.

4 .8 COMMUNICATING

A PLC must communicate with other devices. This is needed to link them to programmingdevices and to other equipments. Many modern instruments and other devices send andreceive information digitally so they are connected to the PLC by some form of network. ThePLCs may form art of a larger system controlled by a mainframe computer. The PLCs must

be linked to each other and to the computer by a network [7].

Links may be made through cables using serial data and parallel data. Parallel data may bethrough a ribbon cable (i.e, the ribbon cable linking a disk drive to a motherboard in acomputer) or a screened multi-core cable.

4 .8.1TWISTED PAIR

When information is sent along two wires, often a twisted pair is used. To reduce the chancesof picking up stray-electromagnetic signals from other lines running alongside it, the twoinsulated copper wires are twisted around each other as shown in fig 4.6.


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4 .8. 2 COAXIAL CABLE

It is a kind of cable used to connect a TV set to rhe aerial. It is also used to connect thetelephone exchanges to the telephone exchanges to the poles near to user. The cable has aninner conductor surrounded by a concentric conductor made from copper mesh and separated

by a layer of insulation. The outer layer is usually grounded[7].

4 .8. 3 F IBRE OPTICS

Fibre optic cable are basically thin glass strands. When light is shone into one end of a strand,it is carried inside the fibre over enormous distance without losing its strength. They are notsubjected to electromagnetic interference and the need to retransmit signals[7].

F ig 4 .6 Different communication cables used in PLC


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Chapter 5

HARDWARE CON F IGURATION O F PLC

5 .1 MICROCONTROLLER:

Here we are using 89c51 microcontroller, which has one full duplex serial data

receiver/transmitter, which is used for serial communication having interface with ICL232

chip. It has also two 16 bits timer/counter namely T0 and T1 which are used for timer and

counter applications. Timer T1 is used to set baud rate for serial communication in program

mode.

5 .2 MEMORY:The system consists of four types of memory:

a. 4k of EE PR OM which is internal to 89c51 microcontroller. This memory is used

to store the operating system. It has address from 0000h to 0fffh. It can only be

accessed when the external access pin of controller is connected to +5v. In our

system this pin is permanently connected with +5v so external program memory is

accessed only when the address is beyond 0fffh.

b. 8k of RAM which is used as data memory. The C PU can read data from and write

data into this memory. This memory has address from 0000h to 1fffh.c. 8k of RAM which is used as data memory as well as program memory. The C PU

can write program codes in and read program codes from this memory. This

memory has address from 2000h to 3fffh.

d. 8k of EE PR OM, which is used as, program memory. The subroutines, which are

helpful in executing the main program, are stored here. This memory has location

from 4000h to 5fffh.

5 .3 PROGRAMMMABLE PERIPHERAL INTER F ACE (PPI):

Here two 8255 are used as PPI. One is used to control the ADC and DAC, while other is

used for Input/output interface. The addresses for the 8255 used to control ADC and DAC

are:

Port A: 6000h

Port B: 6001h

Port C: 6002h


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5 .7 SWITCHES AND INDICATORS:

Switches:

a. Power ON/O FF switch.

b. R eset Switch.

c. Program/ R un mode Switch.Indicators:

a. Power ON/O FF LED(red)

b. R eset LE D(red)

c. Program mode LE D(orange)

d. R un mode LE D(green)

e. Fault LE D(red, green, orange, yellow)

5 .8 DIGITAL INPUT:

DC Input:

We have two digital DC inputs with following specifications:

1. 0v to 5v LOW

2. 20v to 25v- HIGH

3. Optocoupler Isolation.

AC Input:

We have two digital AC inputs with following specifications:

1. 0v to 10v-LOW

2. 20v to 25v- HIGH

3. 47 Hz to 63 Hz frequency.


5 .9 DIGITAL OUTPUT:

DC outputs:

We here have two DC outputs with following specification:

1. 0v t0 3v-0v

2. 3.5v to 5v-24v

3. 0.5amp output current.


AC outputs:

We have two relays as AC outputs with following specification:


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1. 0v to 3v- relay O FF

2. 3.5v to 5v- relay ON


4. R elay with12v, 4ohm.


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Chapter 6

LADDER LOGIC AND PROGRAMMING CONCEPTS O F PLC

Ladder logic is a programming language that represents a program by a graphical diagram

based on the circuit diagrams of relay-based logic hardware. It is primarily used to developsoftware for Programmable Logic Controllers ( PLCs) used in industrial control applications.The name is based on the observation that programs in this language resemble ladders, withtwo vertical rails and a series of horizontal rungs between them as shown in fig 6.1 .

The degree of complexity of a PLC program depends upon the complexity of the application,the number and type of input and output devices and types of instruction used.

The left vertical line of a ladder logic diagram represents the power or energised conductor.

The output coil instruction represents the neutral or return path of the circuit.

The right vertical line which represents the return path of the circuit on a hard-wired controlline diagram is omitted.

Ladder logic diagrams are read from left to right and top to bottom.

R ungs are sometimes referred to as networks. A network may have several control elements but only have one output coil.

F ig 6.1 Basic ladder logic digram


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Ladder logic has contacts that make or break circuits to control coils. Each coil or contact

corresponds to the status of a single bit in the programmable controller's memory. Unlike

electromechanical relays, a ladder program can refer any number of times to the status of a

single bit, equivalent to a relay with an indefinitely large number of contacts[5].

So-called "contacts" may refer to physical ("hard") inputs to the programmable controller

from physical devices such as pushbuttons and limit switches via an integrated or external

input module, or may represent the status of internal storage bits which may be generated

elsewhere in the program.

Each rung of ladder language typically has one coil at the far right. Some manufacturers may

allow more than one output coil on a rung.

-- ( ) -- a regular coil, energized whenever its rung is closed

-- (\) -- a "not" coil, energized whenever its rung is open

-- [ ] -- A regular contact, closed whenever its corresponding coil or an input which

controls it is energized.

-- [\] -- A "not" contact, open whenever its corresponding coil or an input which controls

it is energized.

While ladder logic programs are still common , there are many other ways to program PLCs.

The two common examples are statement list and function block diagrams.

6.1 STATEMENT LIST:

These instructions include an operation and an operand. The operation to be performed is

shown to the left. The operand , the item to be operated on is shown on the right.

6.2 F UNCTION BLOCK DIAGRAM:

These instructions include rectangular functions with inputs shown on the left side of the

rectangle and outputs shown on the right side.


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F ig 6. 2 PLC PRGRAMMING F ORMATS

In addition to L AD , STL and FBD , multiple types of programming languages are used inPLCs. Each type of programming has its advantages and disadvantages. Factors such asapplication complexity , types of programming available for a specific PLC model, and user standards and preferences determine which type of programming is used for an application.

6.3 Programming concepts and example for a Plc: -

6.3.1. Programming with the use of NO, NC switches:

The NO switch is a push switch which is remain in normally open condition, andwhen it is pushed it made a close circuit The NC switch is a switch which leave inclose condition normally, mean provides a close path in normal condition and when itis pressed it makes a open circuit.


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Chapter 8

APPLICATIONS O F PLC

It is difficult to define where a PLC cannot be used.

Proper application of a PLC begins with conversion of information into convenient

parameters to save money, time and effort and hence easy operation in plants and laboratories

The areas where PLC is used maximum are as follows:

1. The batch processes in chemical, cement, food and paper industries which are

sequential in nature, requiring time of event based decisions is controlled by

PLCs.2. In large process plants PLCs are being increasingly used for automatic start up

and shut down of critical equipment. A PLC ensures that equipment cannot be

started unless all the permissive conditions for safe start have seen established. It

also monitors the conditions necessary for safe running of the equipment and trips

the equipment whenever any abnormality in the system is detected.

3. The PLC can be programmed to function as an energy management system for

boiler control for maximum efficiency and safety.

4. In automation of blender reclaimers5. In automation of bulk material handling system at ports.

6. In automation for a ship unloaded.

7. Automation for wagon loaders.

8. For blast furnace charging controls in steel plants.

9. In automation of brick molding press in refractories.

10. In automation for galvanizing unit.

11. For chemical plants process control automation.

12. In automation of a rock phosphate drying and grinding system.

13. Modernization of boiler and turbo generator set.

14. Process visualization for mining application.

15. Criteria display system for power station.

16. As stored programmed automation unit for the operation of diesel generator sets.

17. In Dairy automation and food processing.


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18. For a highly modernized pulp paper factory.

19. In automation system for the printing industry.

20. In automation of container transfer crane.

21. In automation of High-speed elevators.

22. In plastic molding process.23. In automation of machine tools and transfer lines.

24. In Mixing operations and automation of packaging plants.

25. In compressed air plants and gas handling plants.

26. In fuel oil processing plants and water classification plants.

27. To control the conveyor/classifying system.

Thus PLC is ideal for application where plant machine interlock requirements are finalized at

a later stage and need changes during engineering trial runs, commissioning or normal use. It

can be used extensively to replace conventional relay controls in power stations, refineries,

cement, steel, fertilizer, petrochemical, chemical industries etc.

A pplications can thus be extended from monitoring to supervision, control and management.


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