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PLC BASED AUTOMATED SYSTEM IN
PROCESS INDUSTRY
(CEMENT PLANT)
A Graduate Project Report submitted to Manipal University in partial
fulfilment of the requirement for the award of the degree of
BACHELOR OF ENGINEERING
In
Mechatronics Engineering
Submitted by
SHAHID FAIZEE
Under the guidance of
A. SEENIVASAN SUBRAMANYA R. PRABHU B.
Senior Lead Engineer & Assistant Professor
FLSMIDTH Pvt. Ltd.
DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING
MANIPAL INSTITUTE OF TECHNOLOGY
(A Constituent College of Manipal University)
MANIPAL – 576104, KARNATAKA, INDIA
May 2012
DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING
MANIPAL INSTITUTE OF TECHNOLOGY
(A Constituent College of Manipal University)
MANIPAL – 576 104 (KARNATAKA), INDIA
Manipal
11th
April, 2012
CERTIFICATE
This is to certify that the project titled PLC BASED AUTOMATED SYSTEM IN
PROCESS INDUSTRY (CEMENT PLANT) is a record of the bonafide work done by
SHAHID FAIZEE (Reg.No.080929282) submitted in partial fulfilment of the
requirements for the award of the Degree of Bachelor of Engineering (BE) in
MECHATRONICS ENGINEERING of Manipal Institute of Technology Manipal,
Karnataka, (A Constituent College of Manipal University), during the academic year
2012-13.
SUBRAMANYA R. PRABHU B.
Project Guide
Prof. Dr. Divakara Shetty S.
HOD, Mech. & Mfg.
M.I.T, MANIPAL
(On company letter head)
Chennai
11th
April, 2012
CERTIFICATE
This is to certify that the project entitled PLC BASED AUTOMATED
SYSTEM IN PROCESS INDUSTRY was carried out by SHAHID FAIZEE
(Reg. No. 080929282) at FLSMIDTH PVT. LTD., CHENNAI under my
guidance during January, 2012 to May, 2012.
A. Seenivasan
Senior Lead Engineer
FlSmidth Pvt. Ltd.
i
ACKNOWLEDGMENT
Written words have an unfortunate tendency to degenerate genuine gratitude into a formality.
However it is the only way to record one's feelings permanently.
I was bestowed with the golden opportunity to undergo my final semester project training at
FLSMIDTH, Chennai and hence take this opportunity to express my heartfelt thanks to all
those who have been associated with my training.
I express my special thanks to Mr. A. Seenivasan, Senior Lead Engineer in Control System
Division of Electrical and Automation Department, I gained experience and knowledge
about the importance of work culture and planning, which is one of the best of the
establishment; I had the privilege of working in FlSmidth Automation for my final semester
project. I had exposure to:
Knowledge about computer & various packages, which are used in an organization
for its efficient function.
Achieving goals and targets by proper planning & time management.
The importance of communication skill especially when having a group discussion.
I express my heartfelt gratitude to Mr.Rameshkumar Shanmugasundaram, DGM and Head
of Electrical and Automation Department. For providing me with endless support and
encouragement in all my endeavours at every moment during my training.
I also express my thanks to Dr. Divakara Shetty S., HOD of Mechanical and
Manufacturing Department for granting me permission to do my final semester project in
FlSmidth (Automation) Chennai.
I also express my grateful acknowledgement to Mr. Subramanya R. Prabhu B., Assistant
Professor for all his guidance and appreciate his help as my internal project guide.
This acknowledgement is really incomplete if I would fail to express my sincere thanks to
Mr. Vijay Veerapana C., In-Charge, Human Resource Management for giving the
opportunity of working in FlSmidth Automation Division. Last but not the least I thank all
my fellow Trainees for their Co-operation and support.
SHAHID FAIZEE
Mentor
ii
ABSTRACT
Modern PLCs can be programmed in a variety of ways, from ladder logic to more traditional
programming languages such as BASIC and C. Another method is State Logic, a very high-
level programming language designed to program PLCs based on state transition diagrams.
SCADA (SUPERVIOSRY CONTROL AND DATA ACCQUISATION) is a system used to
monitor a plant from a central location. It is widely used in water treatment plants and lately
it has been used in chlorination and pumping station, cement manufacturing process, power,
steel, and etc.The objective of this project is design a PLC BASED AUTOMATED SYSTEM
that can be used to AUTOMATE a CEMENT PLANT using SIEMENS PLC and
FLSMIDTH (ECS) SCADA.
In this Project, PLC Logics have been developed in PLC Software SIEMENS STEP7 (S7).
These PLC logics are then used to develop Motor Blocks. The main languages used in
developing these logics are Ladder Logic or Functional Blocks Diagram. These developed
logics are then used in simulating applications in PLC systems such as Siemens PLCs. The
SIEMENS PLC will then be communicated with Expert Control System (ECS) SCADA
through communication ports. This SCADA is a product of FLSMIDTH.
The Inputs and Outputs defined in the PLC SIEMENS Software are available as buttons
when the Motor Blocks developed and downloaded into the PLC Hardware are integrated
with ECS SCADA. The buttons can be operated from the SCADA Software itself and thus a
Cement Plant can be automated.
These Motor Blocks developed using the PLC logics are used in automation of various
Equipments used in Cement Manufacturing Process such as Crushers, Kiln, Raw Mill,
Grinders, Silo, etc. Through these Motor Blocks we can automate a crusher plant in a Cement
Industry.
The Software used in this project is Expert Control System (ECS) SCADA, PLC SIEMENS
STEP7 (S7) Ladder Logic Programming. The Hardware used is the SIEMENS PLC.
iii
LIST OF TABLES
Table No Table Title Page No
1.1 SCADA Manufacturers 4
1.2 Project Work Schedule 11
3.1 Inputs of Motor Block 19
3.2 Outputs of Motor Block 19
3.3 Inputs of Group Control Block 22
3.4 Outputs of Group Control Block 22
iv
LIST OF FIGURES
Figure No Figure Title Page No
1.1 SCADA Architecture 3
1.2 ControlNet 4
1.3 DeviceNet 5
1.4 Modbus 6
1.5 Profibus 6
1.6 Ethernet 7
1.7 TCP/IP Protocol 8
1.8 Limestone Crusher 11
2.1 Screenshots of SIEMENS SIMATIC STEP7 SOFTWARE 15
2.2 Screenshot of SIEMENS LAD/STL/FBD STEP7 Software (FB1) 16
2.3 Screenshot of SIEMENS LAD/STL/FBD STEP7 Software (FB2) 16
3.1 Motor Block Diagram 19
3.2 Group Control Block Diagram 22
3.3 An Industrial Automation Motor 23
3.4 Screenshots showing different Submods for (i) Start and Stop
(Auto and Local Mode), (ii) Inputs, and (iii) Outputs of Motor
Block
26
3.5 Figure 3.5 Screenshots showing different Submods for (i) Start
and Stop (Auto and Local Mode), (ii) Inputs, and (iii)Outputs
26
3.6 Screenshot showing the Faceplate of a Motor Block (Combination
of three Submods of Motor Block)
27
3.7 Figure 3.7 Screenshot showing the Faceplate of a Group Control
Block (Combination of three Submods of Group Control Block)
27
3.8 A Typical Layout for Crusher Section in Cement Plant
(Run-Time Mode)
28
3.9 Siemens Simatic S7-400 system at rack, left-to-right: power
supply unit, CPU, Ethernet module and communication processor
29
3.10 Quarrying of Limestone from mines 30
3. 11 Limestone before Crushing 31
3.12 Crushed Limestone 31
3.13 Limestone Crushing Process (Flowchart) 31
4.1 Graphical Representation by SCADA through Human Machine
Interface (HMI)
32
5.1 Limestone Crushing Process. 35
v
LIST OF FIGURES (ANNEXURE)
Figure No Figure Title Page No
A1.1.1 Motor Okay 38
A1.1.2 Motor Run 38
A1.1.3 Command 1 39
A1.1.4 Trip 39
A1.1.5 Auto Mode 40
A1.1.6 Local Mode 40
A1.1.7 Motor Run Delay 40
A1.1.8 Return Error 1 41
A1.1.9 Return Error 41
A1.1.10 Alarm Value for different conditions 41
A1.2.1 Group Okay 42
A1.2.2 Group Run 42
A1.2.3 Trip 43
A1.2.4 Group Selection Bit 43
A1.2.5 Group Start 44
A1.2.6 Group Stop 44
A1.2.7 Alarm Value for different conditions 44
A2.1.1 Block Algorithm Editor 45
A2.1.2 Block Algorithm for Motor Block 45
A2.1.3 Block Algorithm for Group Control Block 45
A2.2.1 B-Point Algorithm for Motor Block 46
A2.2.2 B-Point Algorithm for Motor Block 46
A2.2.3 B-Point Algorithm Editor 46
vi
Contents
Page No
Acknowledgement i
Abstract ii
List Of Figures iii
List Of Tables iv
List of Tables
(Annexure) v
Chapter 1 INTRODUCTION 1
1.1 Introduction to SIEMENS PLC and Expert Control System (SCADA) 1
1.2 Motivation 9
1.3 Organization of Report 12
Chapter 2 BACKGROUND THEORY and/or LITERATURE REVIEW 13
2.1 Introduction to Project Title (PLC based Automated System in
Process Industry) 13
2.2 Literature Review 13
2.3 Background Theory and Automation Technology 14
2.4 Summarized Outcome of Literature Review 15
2.5 Conclusions 15
Chapter 3 METHODOLOGY 17
3.1 Work Methodology 17
3.2 Software and Hardware tool Package used 28
3.3 Preliminary Result analysis 29
3.4 Conclusions 30
Chapter 4 RESULT ANALYSIS 32
4.1 Result Analysis (Graphical Representation) 32
4.2 Significance of Result 33
4.3 Conclusions 33
Chapter 5 CONCLUSION AND FUTURE SCOPE 34
5.1 Work Conclusion 34
5.2 General Conclusion 34
5.3 Future Scope of Work 36
REFERENCES 37
ANNEXURES 38
PROJECT DETAILS 48
1
CHAPTER 1
INTRODUCTION
This chapter deals with the following toipcs:
Introduction to the SIEMENS PLC and Expert Control System (ECS) SCADA.
Introduction to various Communication Protocols
Introduction to the Project
Motivation
Organiztion of the Report
1.1 a) Introduction to SIEMENS Programmable Logic Controllers
A PLC (Programmable Logic Controllers) is an industrial computer used to monitor
inputs, and depending upon their state make decisions based on its program or logic,
to control (turn on/off) its outputs to automate a machine or a process.
In automated system, PLC controller is usually the central part of a process control
system.
To run more complex processes it is possible to connect more PLC controllers to a
central computer.
They are based on the Boolean logic operations whereas some models use timers and
some have continuous control.
These devices are computer based and are used to control various process and
equipments within a facility.
PLCs control the components in the DCS and SCADA systems but they are primary
components in smaller control configurations.
PLC HARDWARE:
Hardware Components of a PLC System
Processor unit (CPU), Memory, Input/output, Power supply unit, Programming device, and
other devices.
Central Processing Unit (CPU)
CPU – Microprocessor based, may allow arithmetic operations, logic operators, block
memory moves, computer interface, local area network, functions, etc.
CPU makes a great number of check-ups of the PLC controller itself so eventual errors would
be discovered early.
2
System Busses
The internal paths along which the digital signals flow within the PLC are called busses.
The system has four busses:
The CPU uses the data bus for sending data between the different elements,
The address bus to send the addresses of locations for accessing stored data,
The control bus for signals relating to internal control actions,
The system bus is used for communications between the I/O ports and the I/O unit.
Memory
System (ROM) to give permanent storage for the operating system and the fixed data used by
the CPU.
RAM for data. This is where information is stored on the status of input and output devices
and the values of timers and counters and other internal devices. EPROM for ROM’s that can
be programmed and then the program made permanent.
I/O Sections
Inputs monitor field devices, such as switches and sensors.
Outputs control other devices, such as motors, pumps, solenoid valves, and lights.
Power Supply
Most PLC controllers work either at 24 VDC or 220 VAC. Some PLC controllers
have electrical supply as a separate module, while small and medium series already contain
the supply module.
Programming Device
The programming device is used to enter the required program into the memory of the
processor.
The program is developed in the programming device and then transferred to the memory
unit of the PLC.
1.1 b) Introduction to SCADA and Expert Control System (ECS)
Supervisory Control And Data Acquisition or SCADA is a system used to monitor and
control a plant form a central location. This is not frequently used because of the control
override possibility. SCADA itself changes the control set points quite frequently. It is widely
used in water treatment plants and lately it has been used chlorination and pumping stations.
SCADA system is composed of 3 main elements.
RTU (Remote Telemetry Unit)
HMI (Human Machine Interface)
Communications
3
The function of an RTU is to collect the onsite information and this information is sent to a
central location with the help of the communication element. If system wants to send
information back to the RTU then this communication element take it back too.
The function of the HMI element is to display the information received in an easy to
understand graphical way and also archive all the data received. It is usually a high end
computer system capable of displaying high quality graphics and running advanced and
complex software.
Communication happens through various means. It will happen via data cable within a plant
or through a fibre optic. The communication may happen via radio between different regions.
The major reason of its popularity in the manufacturing industry is that it significantly
reduces the labor costs and improves the performance of the plant. Management can save
time as well because the information is gathered by SCADA at a central location so the
personnel do not have to go and wander about on site.
Another feature of this system which is seldom appreciated is its 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. The SCADA system
may be difficult to configure at first but it is extremely user friendly and easy to use.
Figure 1.1 SCADA Architecture
ADVANTAGES OF SCADA
It significantly reduces 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.
4
It has the capability of displaying the trends. When information is gathered is
displayed graphically, the system shows the developing problems and helps the
management in taking the corrective measures.
SCADA MANUFACTURERS
Table 1.1 SCADA Manufacturers
Introduction to Communication Protocols
ISO/OSI PROTOCOLS:
ControlNet
The Control Net network uses the Common Industrial Protocol (CIP) to combine the
functionality of an I/O network and a peer-to-peer network. ControlNet take precedence over
program uploads and downloads and messaging. Supports a maximum of 99 nodes.
Figure 1.2 ControlNet
NAME OF MANUFACTURER NAME OF SCADA
1. ROCKWELL VIJEO CITECT
2. SIEMEMS SIMATIC WinCC
3. INVENSYS Intouch Wondercare
4. ROCKWELL RSview
5. ABB EMS
6. FLSMIDTH ECS (Expert Control System)
5
Device Net
DeviceNet is mainly used in industrial and process automation. It is based on CAN
technology.
It is a low-cost communication link to connect industrial devices to a network and eliminate
expensive hard wiring. Power and communication supplied over a 4-wire bus. Supports up to
62 devices on the same bus network.
Figure 1.3 DeviceNet
Modbus
Modbus is an open, serial communication protocol based on the master/slave architecture.
The bus consists of a master station, controlling the communication, and of a number of slave
stations.
MODBUS is an application layer messaging protocol, positioned at level 7 of the OSI model
that provides client/server communication between devices connected on different types of
buses or networks. MODBUS is used to monitor and program devices; to communicate
intelligent devices with sensors and instruments; to monitor field devices using PCs and
HMIs. MODBUS is an ideal protocol for RTU applications where wireless communication is
required.
6
Figure 1.4 Modbus
PROFIBUS
PROFIBUS-DP purpose is for larger devices like PCs and PLCs to talk with multiple smaller
devices like sensors, drives, valves, etc. It uses RS-485 for transmission of data. It uses a
shielded twisted pair cable and enables data transmission speeds up to 12 Mbit/sec.
A maximum of 9 segments (trunk line) are allowed on a network. The devices are the
branches coming off the trunk line. Up to 32 individual devices can be connected to a single
segment. That number can be expanded up to 126 if repeaters are used. Each PROFIBUS
segment can be a maximum of 1200 meters in length. There are 10 defined communication
speeds and each has a maximum defined cable length that’s permitted.
Figure 1.5 Profibus
7
Master /Slave
PROFIBUS uses a master/slave configuration for communication. It is usually a single
master device (a PLC) that talks with multiple slave devices (sensors). The master devices
poll the slaves when they have the token. Slave devices only answer when asked a question.
They are passive and the master can be said to be active. The slave devices just collect data
and pass it to the master device when asked to do so.
Ethernet
Ethernet is one of the most widely implemented LAN architecture. It uses a bus, star or tree
topologies. It uses the CSMA/CD access method to handle simultaneous demands. It supports
data transfer rates of 10 Mbps, Fast Ethernet (100 Base-T) - 100 Mbps, and Gigabit Ethernet
– 1000 Mbps.
Figure 1.6 Ethernet
Carrier Sense Multiple Access/Collision Detection (CSMA/CD)
This is a system where each computer listens to the cable before sending anything through
the network. If the network is clear, the computer will transmit. If some other node is already
transmitting on the cable, the computer will wait and try again when the line is clear.
TCP/IP PROTOCOL
Most manufacturers who offer Ethernet compatibility to implement supervisory functions
over equipment controlling plant floor functions use a transmission control protocol/internet
protocol (TCP/IP) for layers 3 and 4 of the OSI model. Some PLC manufacturers offer
programmable controllers with TCP/IP over-Ethernet protocol built into the PLC processor.
This allows the PLC to connect directly to a supervisory Ethernet network. Note that the PLC
can also have a control network with other PLCs.
8
Figure 1.7 TCP/IP Protocol
Introduction to the Project
The project has the following functional parts:
This Project deals with controlling a unidirectional motor using 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.
SCADA (SUPERVIOSRY CONTROL AND DATA ACCQUISATION) is a system
used to monitor a plant from a central location. It is widely used in water treatment
plants and lately it has been used in chlorination and pumping station, cement
manufacturing process, power, steel, etc.
The Application of PLC and SCADA in Cement Manufacturing Industry is very vast.
The various processes in cement manufacturing such as crushing, milling, pre-
heating, grinding as well as logistics all can be automated using PLC and SCADA
system.
SCADA used is Expert Control System which is manufactured by FlSmidth Pvt. Ltd.
Itself.
9
1.2 Motivation
Shortcomings in Manual Systems
Large requirement of labors.
Time consumption will be more.
Health hazards problems due to smoke, dust, etc. around the manufacturing plant.
Not possible to enter high pressure and high temperature areas of the plant.
Difficulty in rapid growth of economy with this manual system.
Importance of the Work in present context
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 is gathered is
displayed graphically, the system shows the developing problems and helps the
management in taking the corrective measures.
It will be the one system that will keep running everything perfectly, smoothly and
fast.
The economy can be grown very high and fast with the development of this
Automated System based on PLC and SCADA.
The development of industries such as Cement Manufacturing Plant, Steel, Power,
etc. can grow very powerful and fast with this help of this Automated System.
Methodology Adopted and it’s Uniqueness
The Automated system is developed by using the motor blocks which have the
following special features:
Separate input and output buttons
Logics developed in easy to use PLC SIEMENS Software
The programming language (Ladder Logic and Functional Block Diagram) is
easy to understand.
There are different signals available to indicate the status of the automated
system.
The automated system is controlled by Expert Control System (ECS) SCADA
which is easy to understand and use.
10
Significance of End Result
The Automated System developed can be used to control and run a unidirectional
motor in a crusher plant of a cement industry.
Labor requirement can be drastically reduced with the development of this Automated
System.
Economy can grow rapidly with the development of this Automated System.
Objective of the work
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 using PLC
controller Hardware Siemens.
The unidirectional Motor thus can be used to control or run different parts of a
Cement Plant.
One typical part is Crusher, which is used to crush the raw materials brought from
quarry mines by quarry trucks and the raw material are the crushed into the crusher.
The function of Crusher is to crush the raw materials such as limestone into tiny balls.
Secondary Objective
The blocks developed using the PLC Software can also be used to control and run a
bi-directional motor.
This bi-directional motor can be used to run different other parts of a cement plant
such as pre-heating tower, kiln tower, mills.
It can also be used for logistics purposes.
Target Specification (Importance of End Result)
The Motor Block developed will help in controlling and running of unidirectional
motor.
These unidirectional motors can be any numbers.
The unidirectional motors can be used to supply power to many isolated parts of a
process industry.
In Cement Plant, Process such as crushing the raw materials (CRUSHER) can be
automated using this motor block.
11
The unidirectional motor can be automated and supply power to the crushers with
minimal human interaction.
Figure 1.9 Limestone Crusher
Project Work Schedule
Table 1.2 Project Work Schedule
Month Detailed Schedule
January Timings: Monday to Friday – 8 a.m. to 5:30 p.m. Lunch Timings : 12:30 pm to 1: 30 pm Saturday and Sunday : Office Holiday
February Timings: Monday to Friday – 8 a.m. to 5:30 p.m. Lunch Timings : 12:30 pm to 1: 30 pm Saturday and Sunday : Office Holiday
March
Timings: Monday to Friday – 8 a.m. to 5:30 p.m. Lunch Timings : 12:30 pm to 1: 30 pm Saturday and Sunday : Office Holiday
April Timings: Monday to Friday – 8 a.m. to 5:30 p.m. Lunch Timings : 12:30 pm to 1: 30 pm Saturday and Sunday : Office Holiday
May
Timings: Monday to Friday – 8 a.m. to 5:30 p.m. Lunch Timings : 12:30 pm to 1: 30 pm Saturday and Sunday : Office Holiday
12
1.3 Organization of the Report
Chapter 1 “INTRODUCTION” describes about Introduction to the SIEMENS PLC and
Expert Control System (ECS) SCADA, introduction to various Communication Protocols,
Introduction to the Project (PLC based Automated System in Process Industry [Cement
Plant]). It also discusses briefly about Motivation of the project.
Chapter 2 “BACKGROUND THEORY” deals with the literature review and background
theory about the PLC and SCADA software developed and their recent development. It also
discusses about the PLC SIEMENS Hardware used.
Chapter 3 “METHODOLOGY” describes about the various methodology used in
developing the motor blocks for controlling the unidirectional motor in PLC Software. It also
discusses about how the faceplates and the crusher sections are designed in the SCADA
Software, and how the PLC and SCADA are communicated to automate a Crusher Section of
a Cement Plant.
Chapter 4 “RESULT ANALYSIS” discusses about the various results obtained throughout
the testing of the project and interpret the result in graphical/tabular form. It also discusses
about the conclusion of the project results obtained at various stages.
Chapter 5 “CONCLUSION AND FUTURE SCOPE OF THE WORK” gives a brief
summary about the project work, a brief summary about the work methodology adopted,
conclusion and significance of the results obtained and future scope of the work.
13
CHAPTER 2
BACKGROUND THEORY
This chapter deals with the following topics:
Introduction to the project title
Literature Review
Background theory
Summarized outcome of Literature Review
Conclusions
2.1 Introduction to the Project Title (PLC based Automated System in Process Industry
[Process Automation])
A process control or automation system is used to automatically control a process such as
chemical, oil refineries, and paper and pulp factories. The PAS often uses a network to
interconnect sensors, controllers, operator terminals and actuators. A PAS is often based on
open standards in contrast to a DCS (distributed control system), which is traditionally
proprietary. However in recent times the PAS is considered to be more associated with
SCADA systems.
Process automation involves using computer technology and software engineering to help
power plants and factories in industries as diverse as paper, mining and cement operate more
efficiently and safely.
2.2 Literature Review
PLC SIEMENS S7 SIEMATIC MANAGER SOFTWARE
STEP 7 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 hardware
Creating and debugging user programs
Configuring 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.
The graphic user interface provided for these tasks is known as the SIMATIC Manager. The
SIMATIC Manager collects all the data and the settings necessary for an automation task
together in a project. Within this project the data are structured according to their function
and represented as objects.
14
EXPERT CONTROL SYSTEM (ECS) SCADA
Hardware independent. ECS/Control Center is based on distributed architecture and
designed for easy integration with numerous hardware products to allow the user to
freely choose the most suitable suppliers for the specific project. A configuration with
main motors from one supplier and process controllers from another is an example
where ECS/Control Center is highly advantageous as the overall integrating system.
Open and configurable. Being a platform for control system solutions, ECS/Control
Center is an open environment that fulfils a wide range of requirements in terms of
local regulations, group standardization and equipment functionality. The
configurable environment of the platform with its high degree of flexibility makes for
customer satisfaction.
2.3 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.
Plant operating settings are then automatically adjusted to achieve the optimum
production. Plant operators can manually override the process automation systems when
necessary.
Present State/Recent Development in the Work Area
Factory owners want their equipment to deliver the highest output with as little
production cost as possible. In many industries including oil, gas and petrochemicals,
energy costs can represent 30 to 50 percent of the total production cost.
In process automation, the computer program uses measurements to show not only how
the plant is working but to simulate different operating modes and find the optimal
strategy for the plant. A unique characteristic of this software is its ability to "learn" and
predict trends, helping speed up the response time to changing conditions.
The software and controls regulate equipment to run at the optimum speed that requires
the least energy. They also ensure the consistency of quality, meaning less energy is
wasted producing products that turn out to be defective, and they forecast when
maintenance is needed so less time and energy is spent stopping and restarting
equipment for routine inspections.
Major blocks of Automated System are: microprocessors, micro controllers and micro
computers, multiprocessors, LANs, SCADA, RTUs (Remote Telemetry Units) and
analog and digital I/O modules.
15
2.4 Summarized Outcome of Literature Review
Replacing human operators in tasks that involve hard physical or monotonous work.
Replacing humans in tasks done in dangerous environments (i.e. fire, space,
volcanoes, nuclear facilities, underwater, etc.)
Performing tasks that are beyond human capabilities of size, weight, speed,
endurance, etc.
Economy improvement: Automation may improve in economy of enterprises, society
or most of humanity. For example, when an enterprise invests in automation,
technology recovers its investment; or when a state or country increases its income
due to automation like Germany or Japan in the 20th Century.
Reduces operation time and work handling time significantly.
Frees up workers to take on other roles.
Provides higher level jobs in the development, deployment, maintenance and running
of the automated processes.
2.5 Conclusions
Process Automated System is the use of control systems and information
technologies to reduce the need for human work in the production of goods and
services.
In the scope of industrialization, process automation is a step beyond mechanization.
Whereas mechanization provides human operators with machinery to assist them with
the muscular requirements of work, automation greatly decreases the need for human
sensory and mental requirements as well.
Process Automated System plays an increasingly important role in the world
economy and in daily experience.
Figure 2.1 Screenshots of SIEMENS SIMATIC STEP7 SOFTWARE
16
Figure 2.2 Screenshot of SIEMENS LAD/STL/FBD STEP7 Software (FB1)
Figure 2.3 Screenshot of SIEMENS LAD/STL/FBD STEP7 Software (FB2)
17
CHAPTER 3
METHODOLOGY
This chapter discusses the following topics:
Work Methodology
Software and Hardware Tool Package used
Preliminary Result Analysis
Conclusions
3.1 Work Methodology
Assumptions Made during the design of Motor Block and Faceplates
The Motor which is controlled is assumed to 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
The Auto, Local Mode and Inputs and Outputs are assumed to predefined i.e. they are
already present as a standard defined submod, only modification to those buttons
needs to be done.
Methodology 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 :
1. Motor Block
2. Group Control Block
Motor Block:
In development of Motor Block, following INPUTS were used :
a) Motor Ready (RDY)
b) Run Feedback (RFB)
c) Local Stop (LSP)
d) Local Start (LST)
18
e) Safety Interlock (SAF)
f) Sequential Interlock (SQI)
g) Process Interlock (PRO)
h) Start Interlock (STI)
i) Overload (OVL)
The OUTPUTS used in Motor Block were:
a) Motor Okay (MOK)
b) Command 2 (COM2)
c) Motor Run (MRN)
d) Command 1 (COM1)
e) Trip (TRIP)
f) Motor Run Delay (MRD)
The STAT Variables defined were :
• Silence
• P_Trig1 (Pulse Trigger 1)
• SR01 (SR flip flop)
• Error_rdy (Error Ready)
• AUTO
• LOCAL
• START
• STOP
• ENABLE
• ALARM
• P_Trig 2 (Pulse Trigger 2)
• P_Trig 3 (Pulse Trigger 3)
• Return On Delay (RetOnT)
• RetMntTIM (Return Monitoring Time from ECS)
• RETERR (Return Error)
• P_Trig 4 (Pulse Trigger 4)
• RS01 (Reset Flip Flop)
• RetFTIM (Return Function Time)
• Irun (Input Run)
• RETERR1 (Return Error 1)
19
Motor Block Diagram:
Figure 3.1 Motor Block Diagram
Table 3.2 Outputs of Motor Block
Table 3.1 Inputs of Motor Block
INPUTS SYMBOLS ABBREV.
ENABLE I0.0 EN
READY I0.1 RDY
RUN FEEDBACK I0.2 RFB
LOCAL STOP I0.3 LSP
LOCAL START I0.4 LST
SAFETY
INTERLOCK
I0.5 SAF
SEQUENTIAL
INTERLOCK
I0.6 SEQ
PROCESS
INTERLOCK
I0.7 PRO
START
INTERLOCK
I1.0 STI
OVERLOAD I1.1 OVL
OUTPUTS SYMBOLS ABBREV.
MOTOR
OKAY
Q0.0 MOK
COMMAND 2 Q0.1 COM2
MOTOR RUN Q0.2 MRN
COMMAND1 Q0.3 COM1
TRIP Q0.4 TRIP
MOTOR RUN
DELAY
Q0.5 MRD
20
Functionality of Motor Block:
The Function Block for the MOTOR BLOCK contains the following logical functions:
In Motor Block, the unidirectional motor runs in local mode only
There is a local start and local stop inputs.
A series of start and stop interlock allow the operation of the device.
The status of the interlock is saved in temporary local data of OB1.
These interlocks are logically combined and declared with the start (local) and stop
(local) inputs in the IN (Input) side when FB1 of the motor is processed.
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 point in time and the duration of the fault/error must be 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.
Group Control Block
In development of Group Control Block following INPUTS were used :
a) Group Ready (GRDY)
b) Group Start Interlock (GSTI)
c) Group Sequential Interlock (GSQI)
d) Start (STA)
e) STP (STP)
f) Group Start Feedback (GSTFB)
g) Group Stop Feedback (GSTPFB)
The OUTPUTS used in Group Control Block are :
a) Group Okay (GOK)
b) Group Run (GRUN)
c) Group Start (GST)
d) Trip
e) Group Stop (GSP)
f) Group Selection Bit (GSEL)
21
The STAT Variables used in Group Control Block are :
a) LECS Local (LECSLOCAL)
b) LECS Auto (LECSAUTO)
c) Local Start (LECSSTR)
d) Local Stop (LECSSTP)
e) Local Selection Bit (LECSSEL)
f) Alarm (ALARM)
Figure 3.2 Cement Process (Flowchart)
22
Group Control Block Diagram
Figure 3.2 Group Control Block Diagram
Table 3.4 Outputs of Group
Control Block
Table 3.3 Inputs of Group Control Block
INPUTS SYMBOLS ABBREV.
ENABLE I0.0 EN
GROUP READY I0.1 GRDY
GROUP START
INTERLOCK
I0.2 GSTI
GROUP
SEQUENTIAL
INTERLOCK
I0.3 GSQI
START I0.4 STA
STOP I0.5 STP
GROUP START
FEEDBACK
I0.6 GSTFB
GROUP STOP
FEEDBACK
I0.7 GSTPFB
OUTPUTS SYMBOLS ABBREV.
GROUP OKAY Q10.0 GOK
GROUP RUN Q10.1 GRUN
GROUP START Q10.2 GST
TRIP Q10.3 TRIP
GROUP STOP Q10.4 GSP
GROUP
SELECTION
BIT
Q10.5 GSEL
23
Functionality of Group Control Block
The FB2 for the GROUP CONTROL BLOCK contains the following logical functions:
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.
The status of the interlock is saved in temporary local data of OB1.
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 FB2
of the motor is processed.
In Group Control Block, the Run Feedback is divided into Group Start Feedback and
Group Run 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.
The point in time and the duration of the fault/error must be specified.
If the start (local and auto) button is pressed and motor enabled, the unidirectional
motor switches itself on, and runs until stop button is pressed.
Figure 3.3 An Industrial Automation Motor
24
Purpose of Motor Block and Group Control Block
The Motor Block developed in SIEMENS SIMATIC MANAGER serves the
following purposes :
The Motor Block developed will help in controlling and running of unidirectional
motor.
These unidirectional motors can be any numbers.
The unidirectional motors can be used to supply power to many isolated parts of a
process industry.
Process industry such as Cement Plant has Crushers, Raw Mill, Grinder, Pre-
Heater, Kiln, etc.
These unidirectional motors can even be used for logistics purposes.
Features of Motor Block and Group Control Block
The Motor Block developed in SIEMENS SIMATIC MANAGER STEP7 has the following
features:
The first feature of this motor block is it can control any unidirectional motor
available and help in automating the various parts of a process industry such as
Cement Plant.
In Cement Plant, Process such as crushing the raw materials (CRUSHER) can be
automated using this motor block.
The unidirectional motor can be automated and supply power to the crushers with
minimal human interaction.
The unidirectional motor subroutine control, monitor and visualize the operation of a
standard one-way drive.
It includes supervision of various types of motion detectors and has facilities like
pulse/pause control and can be programmed as hot stand-by etc.
Advantages of Motor Block and Group Control Block
The following are the advantages of the Motor Block used for controlling a unidirectional
motor:
The Motor Block has individual signals to stop and start the motor, whereas other
blocks usually have same start/stop signals.
25
The Motor Block also has a response signal from the motor to indicate that the motor
is running.
In Motor Block, the time between sending the signal to activate the motor and
receiving the response signal is calculated. If no signal is received in this time, the
motor must be switched off.
There is also a signal to activate the unidirectional motor as compared to other
ordinary blocks.
Design 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.
The Submods consists of the following:
INPUTS defined for the Motor Block Group Control Block in SIMATIC S7 Software
OUTPUTS defined for the Motor Block 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
26
The Screenshots showing how a submod is designed is as shown below:
1. Motor Block Submods
(i) (ii) (iii)
Figure 3.4 Screenshots showing different Submods for
(i) Start and Stop (Auto and Local Mode), (ii) Inputs, and (iii) Outputs of Motor Block
2. Group Control Block Submods
(i) (ii) (iii)
Figure 3.5 Screenshots showing different Submods for
(i) Start and Stop (Auto and Local Mode), (ii) Inputs, and (iii) Outputs
27
The following Screenshots shows how Faceplates are designed from the developed Submods:
Figure 3.6 Screenshot showing the Faceplate of a Motor Block (Combination of three
Submods of Motor Block)
Figure 3.7 Screenshot showing the Faceplate of a Group Control Block (Combination of
three Submods of Group Control Block)
28
Figure 3.7
A Typical Layout for Crusher in Cement Plant (Run-Time Mode)
Testing 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.
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.
3.2 Software and Hardware Tool Package used
The following Software and Hardware Packages were used in development of the Motor
Blocks and the Faceplates:
PLC SIEMENS SIMATIC S7 Software
Expert Control System (ECS) SCADA Software
SIEMENS 400 Station PLC Hardware
29
The First two Software Packages are already discussed in BACKGROUND THEORY
(Chapter 2)
SIEMENS 400 Station PLC Hardware (Programmable Logic Controller)
A programmable logic controller (PLC) or PLC Hardware is a digital computer used for
automation of electromechanical processes, such as control of machinery on factory assembly
lines, amusement rides, or light fixtures. PLCs are used in many industries and machines.
Unlike general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact. Programs to control machine operation are typically stored in battery-
backed-up or non-volatile memory. A PLC is an example of a hard real time system since
output results must be produced in response to input conditions within a limited time,
otherwise unintended operation will result.
Figure 3.8
Siemens Simatic S7-400 system at rack, left-to-right: power supply unit, CPU, Ethernet
module and communication processor
3.3 Preliminary Result Analysis
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 Crushers of a cement
plant
30
Crushers are used for crushing the raw materials brought from the limestone or other
raw materials quarry into tiny balls.
Figure 3.9
Quarrying of Limestone from mines
3.4 Conclusions
The PLC logics were developed in Siemens Step 7 (S7) software.
The language used in developing these logics was Ladder Logic/Functional Block
Diagram.
The logics developed in Step 7 (S7) software were downloaded into Siemens PLC
Controller Hardware.
The Logics in Siemens Step 7 (S7) software were developed in Function Block 1
(FB1) and Function Block 2 (FB2).
Function Block stores the information defined by the user i.e. the inputs, outputs and
STAT variables.
The Motor Block and the Group Control Block are developed in Function FC1 and
Function FC2 respectively.
Function (FC) does not have memory.
The Function Block (FB) on the other hand have memory and is used to store the
information about the Inputs, Outputs and STAT Variables of Motor Block and Group
Control Block
31
Figure 3.10 Figure 3.11
Limestone before Crushing Crushed Limestone
Figure 3.12
Limestone Crushing Process (Flowchart)
32
CHAPTER 4
RESULT ANALYSIS
This chapter discusses the following topics:
Result Analysis (Graphical Representation)
Significance of Result
Conclusions
4.1 Result Analysis (Graphical Representation)
Graphical Interpretation by Expert Control System (ECS) SCADA through Human
Machine Interface (HMI)
Figure 4.1 Graphical Representations by SCADA through Human Machine Interface (HMI)
The ECS SCADA has the capability of displaying the trends. When information
gathered is displayed graphically, the SCADA system shows the developing
problems and helps the management in taking the corrective measures.
33
4.2 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 Crushers of a cement
plant
Crushers are used for crushing the raw materials brought from the limestone or other
raw materials quarry into tiny balls.
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 RTU’s
(Remote Telemetry Units), similar to PLC mounted at different parts of a
manufacturing plant
4.3 Conclusions
The Motor Block and Group Control Block were developed in SIEMENS SIMATIC
STEP7 (S7) Software by integrating the logics developed in Function Block (FB) of
the PLC Software.
The Blocks developed in the Software are then downloaded into the SIEMENS 400
Station PLC Hardware.
The PLC hardware is the integrated with ECS SCADA through an Ethernet Cable.
The faceplates are designed in the ECS SCADA Software by integrating the Submods
created for Motor Block and Group Control Block (three each for Motor and Group
Control Block).The Submods consists of Auto, Local Mode, Inputs and Outputs as
buttons which can operate from the SCADA.
The RTU’s (Remote Telemetry Units) Planted at different parts of manufacturing/
process industry thus communicates through communication protocols like Profibus
(for SIEMENS) to SCADA located at a central location of the plant.
34
CHAPTER 5
CONCLUSION AND FUTURE SCOPE OF WORK
This Chapter deals with the following topics:
Work Conclusion (Summary of Work)
General Conclusions
Future Scope of the Work
5.1 Work Conclusion
Problem Statement/Objectives of the Project
Development of Faceplates (Faceplates contains information about inputs and outputs of PLC
logics) in SCADA ECS (Expert Control System) Software based on:
Development of ladder logics in Siemens Step 7 (S7) PLC Software.
Development of Motor Block and Group Control Block using the developed logics.
Work Methodology Adopted
The Motor Block and Group Control Block were designed in PLC SIEMENS S7
Software
The PLC Motor Logics were downloaded into the PLC 400 Station SIMENS
Hardware
The Submods (six, three each for Motor Block and Group Control Block) were
designed in the ECS SCADA Software, which contains the Inputs, Outputs, Local and
Auto Mode defined in the PLC Software.
The Submods are integrated to design two faceplates, one each for Motor Block and
Group Control Block. The HMI of SCADA shows the trends developed in graphical
form.
5.2 General Conclusion
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.
35
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.
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.
One typical part is Crusher, which is used to crush the raw materials brought from
quarry mines by quarry trucks and the raw material are then crushed into the crusher.
The function of Crusher is to crush the raw materials such as limestone into tiny balls.
Figure 5.1 Limestone Crushing Process
36
5.3 Future Scope of Work
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 can be
employed:
1) Automated Manufacturing
Automated manufacturing refers to the application of automation to produce things in
the factory way. Most of the advantages of the automation technology have its
influence in the manufacture processes.
The main advantages of automated manufacturing are higher consistency and quality,
reduced lead times, simplified production, reduced handling, improved work flow,
and increased worker morale when a good implementation of the automation is made.
2) Industrial automation
Industrial automation deals with the optimization of energy-efficient drive systems by
precise measurement and control technologies. Nowadays energy efficiency in
industrial processes is becoming more and more relevant. Semiconductor companies
like Infineon Technologies are offering 8-bit microcontroller applications for example
found in motor controls, general purpose pumps, fans, and ebikes to reduce energy
consumption and thus increase efficiency. One of Infineon`s 8-bit product line found
in industrial automation is the XC800 family.
3) Process Automation in Mineral Industry
A process control or automation system is used to automatically control a process
such as chemical, oil refineries, and paper and pulp factories. The PAS often uses a
network to interconnect sensors, controllers, operator terminals and actuators. A PAS
is often based on open standards in contrast to a DCS (distributed control system),
which is traditionally proprietary. However in recent times the PAS is considered to
be more associated with SCADA systems.
Process automation involves using computer technology and software engineering to
help power plants and factories in industries as diverse as paper, mining and cement
operate more efficiently and safely.
4) Agriculture Automation
Another Scope of this project is in Agricultural Field such as automated orange
sorting, autonomous tractors, and also in robotic strawberry pickers.
5) Numerical Control (NC) Automation
Numerical Control (NC) Automation includes automating machines such as mills,
grinders, cranes, etc. Such machines are called as Computer Numerical Control
(CNC) Machines. These Machines are controlled through G-code Programming i.e.
through Numerical Control (NC).
37
REFERENCES
Reference / Hand Books
[1] “SIEMENS STEP 7(S7) ACESYS-Reference Manual”, PEPPERL+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
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
38
ANNEXURE
A1] PLC Logics for different Input and Output Conditions for Motor Block and Group
Control Block
1. Motor Block
1) Motor Okay
Figure A1.1.1 Motor Okay
2) Motor Run
Figure A1.1.2 Motor Run
39
3) Command 1
Figure 1.1.3 Command 1
4) Trip
Figure 1.1.4 Trip
40
5) Auto Mode
Figure 1.1.5 Auto Mode
6) Local Mode
Figure 1.1.6 Local Mode
7) Motor Run Delay Timer
Figure 1.1.7 Motor Run Delay Timer
41
8) Return Error 1
Figure 1.1.8 Return Error 1
9) Return Error
Figure 1.1.9 Return Error
10) Alarm Value for different conditions
Figure 1.1.10 Alarm Value for Different Conditions
42
The Conditions are:
Return Error
Motor Ready
Local Stop
Safety Interlock
Start Interlock
Process Interlock
Sequential Interlock
Overload
2. Group Control Block
1) Group Okay
Figure 1.2.1 Group Okay
2) Group Run
Figure 1.2.2 Group Run
43
3) Trip
Figure 1.2.3 Trip
4) Group Selection Bit
Figure 1.2.4 Group Selection Bit
44
5) Group Start
Figure 1.2.5 Group Start
6) Group Stop
Figure 1.2.6 Group Stop
7) Alarm Value for different Conditions
Figure 1.2.7 Alarm Value for Different Condition
The Conditions are:
Group Ready
Group Start Interlock
Group Sequential Interlock
45
A2] SCADA Algorithms (Screenshots)
1. Block Algorithm
Figure A2.1.1 Block Algorithm Editor
Figure A2.1.2 Block Algorithm for Motor Block
Figure A2.1.3 Block Algorithm for Group Control Block
46
2. B-Point Algorithm
Figure A2.2.1 B-Point Algorithm for Motor Block
Figure A2.2.2 B-Point Algorithm for Group Control Block
Figure A2.2.3 B-Point Algorithm Editor
47
A3] Codes for buttons on Motor and Group Control Faceplates
1. Motor Block (Button 1)
#
call objectuserword(_self, 1, 0)
qobjectuserword(_self, _TRUE)
>=0
vis 1
<0
vis 0
2. Group Control Block (Button 1)
#
call objectuserword(_self, 1, 4)
qobjectuserword(_self, _TRUE)
>=4
vis 1
<4
vis 0
Note: Other Buttons can be created in a similar way by manipulating the values from 0 to 4in
motor block button code and from 4 to 0 in group control block button code.
48
PROJECT DETAILS
Student Details
Student Name SHAHID FAIZEE
Register Number 080929282 Section / Roll No 57
Email Address [email protected] Phone No (M) +91-9176254511/
+91-9742353684
Project Details
Project Title PLC BASED AUTOMATED SYSTEM IN PROCESS INDUSTRY
(CEMENT PLANT)
Project Duration 23rd
January, 2012 to 18th
May, 2012
Date of reporting 23rd
January, 2012
Organization Details
Organization Name FlSmidth Pvt. Ltd.
Full postal address
with pin code
FlSmidth House, 34, Egatoor, Kelambakkam (Rajiv Gandhi Salai)
Chennai
Tamil Nadu – 603 103
INDIA
Tel + 91 44 4748 1000 / 2741 1000
Fax + 91 44 2747 0301/0302
Website address www.flsmidth.com
Supervisor Details
Supervisor Name A. SEENIVASAN
Designation Senior Lead Engineer
Full contact address
with pin code
14-A1,Sugan Vihar Apartments, Telephone Colony, Adambakkam,
Chennai-600 008 (Tamil Nadu State), INDIA
Email address [email protected] Phone No (M) +91-9884401373
Internal Guide Details
Faculty Name SUBRAMANYA R. PRABHU B.
Full contact address
with pin code
Dept of Mechanical & Manufacturing Engg., Manipal Institute of
Technology, Manipal – 576 104 (Karnataka State), INDIA
Email address [email protected]
