plC BASED AUTOMATED SYSTEM IN PROCESS INDUSTRY (CEMENT PLANT)NAME: SHAHID FAIZEECOLLEGE: MANIPAL INSTITUTE OF TECHNOLOGY REGISTRATION NO.: 080929282ROLL NO.: 57YEAR: IV (8th Semester)

A thesis presentation presented in partial fulfillment of the requirements for the degree of

Bachelor of Engineering in Mechatronics

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LIST OF CONTENTSTOPICS COVEREDSLIDE NUMBER INTRODUCTION5LITERATURE REVIEW/BACKGROUND THEORY15IMPORTANCE OF THE PROJECT20OBJECTIVES OF THE PROJECT22METHODOLOGY25RESULTS OBTAINED53FINAL CONCLUSION56FUTURE SCOPE OF THE PROJECT59REFERENCES60

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Beginning course details and/or books/materials needed for a class/project.21

LIST OF FIGURES3FIGURE NO.FIGURE TITLESLIDE NUMBERFIGURE 1Components of a PLC Hardware6FIGURE 2A schematic View of SCADA Architecture10FIGURE 3A Schematic Representation of Working of SCADA11FIGURE 4Profibus Cable14FIGURE 5Screenshot of SIEMENS SEMATIC MANAGER STEP 7 (S7) Software17FIGURE 6Screenshot of SIEMENS LAD/STL/FBD (FB1) STEP 7 Software18FIGURE 7Screenshot of SIEMENS LAD/STL/FBD (FB2) STEP 7 Software19FIGURE 8A Pictorial View of SCADA (ECS) SOFTWARE in Control System Lab21FIGURE 9Limestone Crushing Process 23FIGURE 10Motor Block Diagram30FIGURE 11 Group Control Block Diagram35

A schedule design for optional periods of time/objectives. 31

4FIGURE NO.FIGURE TITLESLIDE NUMBERFIGURE 12 Screenshot showing Submod for Start and Stop (Auto and Local Mode) 42FIGURE 13Screenshot showing Submod for Inputs 43FIGURE 14Screenshot showing Submod for Outputs of Motor Block 44FIGURE 15Screenshot showing Submod for Start and Stop (Auto and Local Mode)45FIGURE 16Screenshot showing Submod for Inputs 46FIGURE 17Screenshot showing Submod for Outputs47FIGURE 18Screenshot showing the Faceplate of a Motor Block (Combination of three Submods of Motor Block) 48FIGURE 19Screenshot showing the Faceplate of a Group Control Block (Combination of three Submods of Group Control Block) 49FIGURE 20A Typical Layout for Crusher in Cement Plant (Run-Time Mode) 50FIGURE 21Graphical Interpretation by Expert Control System (ECS) SCADA through Human Machine Interface (HMI) 53

LIST OF FIGURES

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INTRODUCTION

This Project deals with controlling a unidirectional motor for crusher section of a cement plant using a PLC controller hardware such as Siemens or ABB or Rockwell. In this project Siemens PLC is used.

PLC Hardware is nothing but an industrial computer used to monitor inputs, and depending upon their state makes decision based on its program or Logic to control (turn on/off) its output to automate a machine or a process.

The PLC will then be integrated with SCADA.

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Objectives for instruction and expected results and/or skills developed from learning. 51

POWER SUPPLYSIEMENS (S7) PLC PROCESSORETHERNET MODULEPROFIBUS MODULEINTRODUCTIONPROFIBUS interface(9-pin D-sub femaleconnector)Components of a PLC HardwareFIGURE 16

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SCADA (SUPERVIOSRY CONTROL AND DATA ACCQUISATION) is a system used to monitor a plant from a central location. It is widely used in process and factory industry. The Application of PLC and SCADA in Cement Manufacturing Industry is very vast.

SCADA used is Expert Control System (ECS) which is a product of FlSmidth Private Limited.

INTRODUCTION7

Relative vocabulary list. 71

Project compose of three main Components :

PLC (Programmable Logic Controller) HMI (Human-Machine Interface) /SCADA Communications

INTRODUCTION8

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COMPONENTS OF PROJECT

PLC The function of an PLC is to collect the onsite information and this information is sent to a central location with the help of the communication element. HMI/SCADA The function of HMI/SCADA is to display the information received in an easy to understand graphical way and also to archive all the data received.COMMUNICATION It happens through various means. It happens via data cable within a plant or through a fiber optic or via radio between different region.INTRODUCTION9

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PROJECT ARCHITECTUREINTRODUCTIONFIGURE 2PROJECT Architecture10

PCPLCI/OI/OI/OI/OEthernet ProfibusProfibusProfibusProfibus

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SCADA SUPPLIERS FLSMIDTHECS (Expert Control System)SIEMENSSIMATIC WinCCINVENSYSIntouch WondercareROCKWELLRSViewABBEMS Schneider Electric Vijeo Citec

INTRODUCTION11

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COMMUNICATION PROTOCOLS

PROFIBUS MODBUSCONTROLNET DEVICENET

In this project PROFIBUS Protocol is used.INTRODUCTION12

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PROFIBUS It is used in large devices such as PCs and PLCs to talk with multiple smaller devices like sensors, drives, valves, etc. It uses RS-485 for transmission of data. Profibus also uses a master/slave configuration for communication. Supports upto 126 devices.

Profibus CableINTRODUCTIONFIGURE 413

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PLC SIEMENS STEP7 (S7) SIMATIC MANAGER SOFTWARE STEP7 is the basic programming and configuration software for SIMATIC. It is made up of a series of applications, each of which does a specific job within the scope of programming an automation task, such as:Configuring and assigning parameters to the hardwareCreating and debugging user programsConfiguring networks and connections The basic package can be extended by a range of optional packages, for example, additional programming language packages such as SCL, S7 Graph, or HiGraph. LITERATURE REVIEW14

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Background Theory and Automation Technology

In the absence of process automation, plant operators have to physically monitor performance values and the quality of outputs to determine the best settings on which to run the production equipment. Maintenance is carried out at set intervals. This generally results in operational inefficiency and unsafe operating conditions.

Process automation simplifies this with the help of sensors at thousands of spots around the plant that collect data on temperatures, pressures, flows and so on. The information is stored and analyzed on a computer and the entire plant and each piece of production equipment can be monitored on a large screen in a control room.

LITERATURE REVIEW15

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Plant operating settings are then automatically adjusted to achieve the optimum production. Plant operators can manually override the process automation systems when necessary.

Screenshot of SIEMENS SEMATIC MANAGER STEP 7 (S7) SoftwareLITERATURE REVIEWFIGURE 516

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Screenshot of SIEMENS LAD/STL/FBD (FB1) STEP 7 SoftwareLITERATURE REVIEWFIGURE 617

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SCREENSHOT OF SIEMENS LAD/STL/FBD (FB2) STEP 7 SOFTWARELITERATURE REVIEWFIGURE 718

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IMPORTANCE OF THE PROJECTWith the development of this project, it will significantly reduces the labor cost and improves the performance of plant in the manufacturing industry.

Operators can save time as well because information is gathered by SCADA at a central location so that a personnel does not have to go and wander about on site.

It has the capability of displaying the trends. When information gathered is displayed graphically, the system shows the developing problems and help the operators in taking the corrective measures.

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A Pictorial View of SCADA (ECS) SOFTWARE in Control System LabIMPORTANCE OF THE PROJECTFIGURE 820

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OBJECTIVES OF THE PROJECTThe Automated System developed can be used in various processes of Manufacturing Industry such as Cement Plant.

The main focus of this project is controlling a unidirectional motor for crusher section of a cement plant using Siemens PLC controller Hardware .

In Cement Industry, Crusher is used to crush the raw materials such as limestone brought from quarry mines by quarry trucks into tiny balls.

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OBJECTIVES OF THE PROJECT

Limestone Crushing ProcessFIGURE 922

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METHODOLOGY

Assumptions Made during the design of Motor Block and Group Control Block23The Motor which is controlled is assumed to be unidirectional motor i.e. Motor runs only in forward direction.

It is assumed that only single motor can be controlled by a Motor Block.

The Group Control Block can however control n number of Motors, where n can be any number grater than one.

The Auto, Local Mode and Inputs and Outputs are assumed to predefined.

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Software and Hardware Tool Package used:

PLC SIEMENS SIMATIC S7 Software Expert Control System (ECS) SCADA Software SIEMENS 400 Station PLC Hardware

METHODOLOGY

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25Methodology and Experimental Setup for development of Motor Block and Group Control Block

The PLC logics were developed in Step 7 (S7) Siemens Software.

Two different blocks were developed using Siemens Software namely :Motor Block Group Control Block

METHODOLOGY

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26 PURPOSE OF MOTOR BLOCK AND GROUP CONTROL BLOCK

The Motor Block developed will help in controlling and running of unidirectional motors.These unidirectional motors can be any numbers.The unidirectional motors can be used to supply power to crusher, kiln, preheater, logistics, etc. of a cement plant.

METHODOLOGY

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27In development of Motor Block, following INPUTS were used:

MCC SignalsMotor Ready (RDY)Run Feedback (RFB)Local Stop (LSP)Local Start (LST)Overload (OVL)

InterlocksSafety Interlock (SAF)Sequential Interlock (SQI)Process Interlock (PRO)Start Interlock (STI)

METHODOLOGY

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28 The OUTPUTS used in Motor Block were:

Motor Okay (MOK) Command 1 (COM1) Motor Run (MRN)Trip (TRIP) Motor Run Delay (MRD)

METHODOLOGY

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29 MOTOR BLOCK :METHODOLOGYFIGURE 10 Motor Block Diagram

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30 FUNCTIONALITY OF MOTOR BLOCK:

In Motor Block, the unidirectional motor runs in local mode and can be made to run in auto mode through group control block.

There is a local start and local stop inputs for operating the motor in local mode.

A series of interlocks allow the operation of the device.These interlocks are logically combined and declared in the IN (Input) side when Function Block of the motor is processed.

METHODOLOGY

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31FUNCTIONALITY OF MOTOR BLOCK: Run Feedback from the motor must appear within a certain time. Otherwise it is assumed that an error or fault has occurred. This function then stops the motor.The time and the duration of the fault/error is specified. If the start (local) button is pressed and motor enabled, the unidirectional motor switches itself on, and runs until stop button is pressed.When the device is switched on a timer starts to run. If the response signal is not received before the timer has expired, the unidirectional motor will stop.

METHODOLOGY

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32In development of Group Control Block following INPUTS were used : Group Ready (GRDY) Group Start Interlock (GSTI) Group Sequential Interlock (GSQI) Start (STA) Stop (STP) Group Start Feedback (GSTFB) Group Stop Feedback (GSTPFB)

METHODOLOGY

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33 The OUTPUTS used in Group Control Block are :

Group Okay (GOK) Group Run (GRUN) Group Start (GST) Trip Group Stop (GSP) Group Selection Bit (GSEL)METHODOLOGY

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34GROUP CONTROL BLOCKMETHODOLOGY

FIGURE 11 Group Control Block Diagram

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35FUNCTIONALITY OF GROUP CONTROL BLOCK:

In Group Control Block, the unidirectional motor runs in both local and auto mode.There are only two interlocks namely Start interlock and Sequential interlock in contrary to four interlocks in Motor Block. The Safety interlock and Process interlock are missing in Group Control Block.As in Motor Block, the various interlocks allow the operation of the unidirectional motor.

METHODOLOGY

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36FUNCTIONALITY OF GROUP CONTROL BLOCK:

Like in Motor Block, these interlocks are logically combined and declared with the start (local and auto) and stop (local and auto) inputs in the IN (Input) side when Function Block of the motor is processed.

In Group Control Block, the Run Feedback is divided into Group Start Feedback and Group Stop Feedback. This Start and Stop Feedbacks from the motor must appear within a certain time. Otherwise it is assumed that an error or fault has occurred. This function then stops the motor.

METHODOLOGY

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37FEATURES OF MOTOR BLOCK AND GROUP CONTROL BLOCKThe Motor Block and Group Control Block has number of features in terms of interlocks present. There are four different types of interlocks. They are :Safety Interlock : The function of this interlock is to provide the safe operation of the unidirectional motor for example proper temperature and pressure conditions, etc..This interlock is applicable only to individual unidirectional motor and hence absent in Group Control Block. Sequential Interlock : Its function is to provide the sequential operation of a number of motors. If any motor in the sequence fails, it will give a return error.

METHODOLOGY

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38 FEATURES OF MOTOR BLOCK AND GROUP CONTROLBLOCK

Process Interlock : The function of this Interlock is to provide smooth operation (motion detector) of the number of processes taking place in the individual unidirectional motor. Since the processes are for a single individual motor, this interlock is present only in Motor Block.

Start Interlock : The function of this interlock is to provide the proper starting of the unidirectional motor(s).METHODOLOGY

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39METHODOLOGYDesign of Faceplates for Motor Block and Group Control Block

After the development of Motor Block and Group Control Block in SIEMENS S7 Software and downloading the block logics into the PLC Hardware, faceplates are designed for motor blocks and group control block.

To develop the Faceplates, it is necessary to create Submods. Submods are the parts of faceplates.

For a Motor Block and Group Control Block, total six Submods will be created.

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40 SUBMODSThe Submods consists of the following:

INPUTS defined for the Motor Block and Group Control Block in SIMATIC S7 Software. OUTPUTS defined for the Motor Block and Group Control Block in SIMATIC S7 Software. The Modes i.e. the Local Mode and Auto Mode and Start and Stop Buttons will also be present in a submod.

METHODOLOGY

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The Screenshots showing how a submod is designed is as shown below: 1. Motor Block Submods METHODOLOGYFigure 12 Screenshot showing Submod for Start and Stop (Auto and Local Mode)

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METHODOLOGYFigure 13 Screenshot showing Submod for Inputs of Motor Blcok

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METHODOLOGYFigure 14 Screenshot showing Submod for Outputs of Motor Block

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442. Group Control Block Submods

METHODOLOGYFigure 15 Screenshot showing Submod for Start and Stop (Auto and Local Mode)

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METHODOLOGYFigure 16 Screenshot showing Submod for Inputs of Group Control Block

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METHODOLOGYFigure 17 Screenshot showing Submod for Outputs of Group Control Block

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47The following Screenshots shows how Faceplates are designed from the developed Submods:

METHODOLOGYFigure 18 Screenshot showing the Faceplate of a Motor Block (Combination of three Submods of Motor Block)

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METHODOLOGYFigure 19 Screenshot showing the Faceplate of a Group Control Block (Combination of three Submods of Group Control Block)

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METHODOLOGYFIGURE 20A Typical Layout for Crusher in Cement Plant (Run-Time Mode)

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50Testing of Motor Block and Group Control Block with PLC Hardware and SCADA

The PC in which the logics (Motor Block and Group Control Block) are created is connected to the PLC Hardware through an Ethernet Cable.

The Program i.e. the logics are transferred through this Ethernet module from the PLC Software to PLC Hardware.

The SCADA and PLC Hardware are then made to communicate with each other through Ethernet Communication Protocol.

METHODOLOGY

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51Testing of Motor Block and Group Control Block with PLC Hardware and SCADA

The Crusher section created in the ECS software is then converted from editor mode to run time mode.

In this run time mode, the buttons present on the faceplates for the crusher section can be operated and thus, the crusher (section) of a cement plant can be automated.

METHODOLOGY

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RESULT OBTAINED52

Result Analysis (Graphical Representation) FIGURE 21 Graphical Representation of Human Machine Interface (HMI) showing the status of starting of Unidirectional Motor

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53 SIGNIFICANCE OF RESULT

The logics were used to develop a Motor Block and a Group Control Block.

The two Blocks developed and downloaded into PLC Hardware can be integrated with SCADA and be used to control a unidirectional Motor in Crusher of a cement plant. RESULT OBTAINED

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54SIGNIFICANCE OF RESULT

The Submods were made in ECS SCADA Software, which contains Auto, Local Mode, and Inputs and Outputs defined in the SIEMENS PLC Software as separate Submods.

These six Submods (three each for Motor Block and Group Control Block) are the integrated into two faceplates one each for Motor Block and Group Control Block.

The Inputs and Outputs will be visible as buttons in the faceplates and can used to operate the manufacturing plant through SCADA from a central location with RTUs (Remote Telemetry Units), similar to PLC mounted at different parts of a manufacturing plant.

RESULT OBTAINED

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FINAL CONCLUSION55 With the development of this project, it will significantly reduce the labor cost and improves the performance of plant in the manufacturing industry.

Management can save time as well because information is gathered by SCADA at a central location so that personnel do not have to go and wander about on site.

It has the capability of displaying the trends. When information gathered is displayed graphically, the system shows the developing problems and helps the management in taking the corrective measures.

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It will be the one system that will keep running everything perfectly, smoothly and fast.

The Automated System developed can be used in various processes of Manufacturing Industry such as Cement Plant.

The main focus of this project is controlling a unidirectional motor used in a Crusher section of a Cement Plant using Siemens PLC controller Hardware.

The unidirectional Motor thus can be used to control or run different parts of a Cement Plant.

FINAL CONCLUSION

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PRESENT SCOPE OF THE PROJECT57

The Automated System developed can be used for the various other purposes apart from Cement Industry. Following are some of the areas where this automation system is employed:

Automated Manufacturing Industrial automation Process Automation in Mineral Industry Agriculture Automation Numerical Control (NC) Automation

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REFERENCES 58

Reference / Hand Books

[1] SIEMPPERLENS STEP 7(S7) ACESYS-Reference Manual, PE+FUCHS Publisher (Germany), Edition 2008, Part No. 194576 08 /10 05 [2] SENSORS FOR FACTORY AUTOMATION, PEPPERL+FUCHS Publisher (Germany), Edition 2008, Part No. 193679 04/08 01

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Web [1] PLC Basics and Communication Protocols, www.plcmanual.com [2] Expert Control System (ECS) SCADA Software, www.flsmidth.com/automation [3] SIEMENS SIMATIC STEP7 (S7) Software, www.automation.siemens.com REFERENCES

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