APPLICATION OF PLC AUTOMATION IN IRON & STEEL

APPLICATION OF PLC AUTOMATION IN IRON & STEEL INDUSTRY

B. Tech 4th Year Industrial Training Presentation

Date- 22/11/2016

Presented ByAvidipta De ,11700513009

Arisha Ghosh ,11700513007Ritam Dholay,11700513029

Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

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Fig: S7-200 PLC Module

Contents• Company Overview• Introduction to PLC• Operation of PLC• Models of PLC• HMI Development• Sample HMI• Sinter Plant HMI Development• Blast Furnace HMI Development• Equipment Snapshots• Conclusion• References

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

Fig: Workdesk

Company Overview

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

• Primetals Technologies India Pvt. Ltd, a J.V of Siemens VAI & Mitsubishi Industries.

• Area of expertise: Iron & Steel Making, Processing lines, Coal & raw material handling plants.

Introduction to PLC • Programmable Logic

Controllers (PLCs) are used in commercial and industrial applications.

• PLCs consist of input modules or points, a Central Processing Unit (CPU), and output modules or points.

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

Fig: PLC BLOCK Diagram

Operation of PLC• An input accepts a variety of

digital or analog signals from various field devices converts them into a logic signal that can be used by the CPU.

• The CPU makes decisions and executes them.

• Output modules converts control instructions from the CPU into a digital/analog signal that can be used to control various field devices.

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

Fig: S7-200 PLC Scan

Models of PLC• Siemens : S7-200, S7-400, S7-500.• Honeywell : ML 200, ML 200R• Allen Bradley : 1785 PLC5, SLC 500

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

Fig: S7-500 PLC Setup

HMI Development• HMI(Human Machine Interface) is the interface module

which the operator has to face.• This screen provides a total, complete, comprehensive layout

of a particular process in a plant.• The entire process can be controlled , monitored via the

HMI.• Inner workings and programs can also be accessed and edited

by necessary means.• Used WINCC(Company provided software ) for this purpose.• All developments based on S7-400 PLC.

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

Sample HMI

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

Fig: Blast Furnace HMI Screen

Project Details

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

• Assigned to running project for Jindal Steel and Power Limited(JSPL), Andul, Odhissa.

• Worked on two different processes: Sinter Plant & Blast Furnace.

Sinter Plant HMI Development

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

• Designed HMI pages for Sinter Plant using WINCC software.

Blast Furnace HMI Development

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

• Designed HMI pages for Blast Furnace using WINCC software.

Equipment Snapshots

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

Fig: S7-500 PLC Bus Connector Fig: S7-500 PLC Module

Conclusion

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

• An inner view of the actual workings of PLC and its applications were seen.

• Had the opportunity to do hands on work in Industrial level.

• Learnt the application of theory in actual world.

• Enriching experience worth remembering. Fig: S7-500 PLC Motor Functions

References

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Department Of Applied Electronics And Instrumentation Engineering, RCCIIT Canal South Road, Beliaghata , Kolkata, West Bengal 700015

• SIMATIC S7-200 User Manual.• Images Courtesy: Primetals Technologies

India.• WINCC User manual.• Siemens S7-200 Training Manual.• Process Control & Applications – Surekha

Bhanot.

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Department Of Applied Electronics And Instrumentation Engineering, RCCIITCanal South Road, Beliaghata , Kolkata, West Bengal 700015