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7/29/2019 Project Plc
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v oca t i ona l t r a in ing PROJECTr epo r t
7/29/2019 Project Plc
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CONTENTS
I n t roduc t ion System descr ipt ion Con tro l Phi losoph y Pro cess Flow chart Ladder Diagram SCADA Design Auto CAD Drawing
Genera l Ar rangem ent PLC Co nt ro l Circu it Single Line D iagram Pow er Circui t Legend Detai ls
Bil l o f M ater ia l (B .O.M ) Sheet M etal Calculat ion o f Con tr ol Panel Pro ject Cost ing Evaluat ion (Cost An alysis)
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INTRODUCTION
The concerned pr oject is based on W ater Contro l System . In th is project oper at ions perform ed in anamu sem ent park are logical ly designed in ladder logic.
In th is p ro ject the fo l lowing so f tw are and hardware are used.
Sof tware:
# Operat ing System : M icrosoft W indow s XP Professional
Version 2002 Service Pack 3
# PLC Progr am m ing : RSLogix 500 Engli sh 7.00.0 0 (CPR 7)
# SCADA Designin g : RSView 32 7.20.0 0 (CPR 7)
# Em ulat or : RSLogix Em ulat e 500
# Comm unicat ion Sof tw are : RSLinx Classic 2.51.00 (CPR 7)
# Com m unication Protocol : DH-485; [ DH - Data High w ay ]
# Com m unication Dr iver (wi t h PLC) : AB _DF1
# Com m unication Dr iver (wi t hout PLC) : EM U-500# Drawin g : M S Paint
# Docum enta t ion : M icrosof t Of f ice 2003, 2007
# Ut i l i ty Soft w are : a) Rockwel l Aut om ation USB CIP Dr iverPackage
b) PDF Creato r
c) Adobe Reader 9.3
Hardware :
# PC : Int el Core 2 Duo CPU 3.06 GHz
Intel Orig inal M oth erboard
2 GB DDR2 RAM , 320 GB SATA HDD
14 Colour TFT M onit or
# PLC : M icroLogix 1000, 1761-L16BWA220V AC/ 24V DC
Specification:
10 po in t i npu t / 6 po in t ou tpu t
Bus current draw : - 5V DC 0.04A
24V DC 0.105A
Inpu t r ange: - 4-20m A, 0-10V DC, Class2
Outp ut range: - 4-20m A, 0-10V DC
# PC-> PLC Com m unicat ion Port : 1761-CBL-PM 02, Series C
#M ake [PLC & PC->PLC Com m unicat ion
Port] : Al len-Bradley
#M anufacturer : Rockwel l Au tom at ion
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Sy St em deScr ipt ion
The main comp onent s used in Water Contr o l System are as fo l low s:
1. Limi t sw i tches2. Solen oid Valve3. Level Sensor4. Pu m p m o t o r5. Indicat ing Lamp s
Limit switches: A mechanical l imi t switch is aelectromechanical device which can be used to
determ ine the physica l posi t ion o f equ ipment . The l im i t
switch gives ON/ OFF out put that corr espond s to p osi t ion
of equipment. I t operates through pressure act ing upon
the swi tch and the s ta te o f the swi tch is de termined
accordingly.
As seen from the given f igure an extension on a valve
shaf t m echan ica l ly t r ips a l im i t sw i tch as i t m oves f rom open to shut o r shut t o open.
In W ater Cont ro l System in w ater am usement park, l im i t swit ch is used to sense the posi t ion of cart (cart
det ect l im it sw itch ) . The l im it swit ch also senses w heth er the r ide is fu l l w i th t he tou r group. As the cart
is over lim i t swit ch and the r ide is fu l l , limi t switch changes state to ON state and th e consequent act ion
fo l lows.
Soleno id valve: A solenoid valve is an electrom echanical valve for use w ith l iquid or gas. The valve is
contro l led by an electr ic current t hrou gh a solenoid. In the case of a tw o-port valve the f low is switched
on or o f f and in the case o f a th ree-por t va lve, the ou t f low is sw i tched be tween the t w o ou t le t por ts .
Solenoid valves are the most frequently used contro l e lements in f lu id ics. Their tasks are to shut off ,
re lease, dose, d istr ibute or mix f lu ids. A solenoid valve has
tw o main parts: the solenoid and the valve. The solenoid
converts e lectr ical energy into mechanical energy which, in
tur n, open s or closes the valve m echanical ly.
In W ater Contro l System , the solenoid valve is used to cont ro l
the ou t f low and in f low o f w ater in the tank. A so leno id valve
each a t t he in le t ( f illing valve ) and exi t (out le t va lve ) o f tank is
present and the level sensors senses w ater level and actuat es
the va lve w h ich in tu rn contro ls the f low o f w ater f rom p ipes
both a t in le t and ou t le t .
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Level Sensor: Level sensor is just an
electronic sensor t hat is used t o sense level of
a f lu id. Level sensors detect the level of
substances that f low, including l iquids,
slurr ies, granular mater ia ls, and powders.
Flu ids and f lu id ized sol ids f low to become
essentia l ly level in their containers (or other
physical boundar ies) because of gravi ty
whereas most bulk sol ids p i le at an angle of
repose to a peak. The substance to be
m easured can be inside a container or can be
in i ts natur al form (e.g. a r iver or a lake).
In t h is part icular appl icat ion , the level sensor
is used to sense the l iquid level in the water
tank. A level sensor is present each at t he t op
and the bo t tom o f the tank . When the level
full sensor detects the f lu id, i t actuates in let valve to close and when the level empty sensor detects a
par t icu la r min imu m leve l o f f lu id in the tank, i t actua tes the ou t le t va lve to c lose the ou t f low o f w ater .
P um p m o t o r: The pum p m otor is a dev ice tha t is used to pum p w ater . In our app l icat ion t he pum p
motor is used to opera te a water je t . The pump motor is fo r
generat ion of water jet. Here we use a single phase induction
m otor fo r t he genera t ion o f w ater je t .
The speci f icat ion of t he m oto r used is as fo l low s:
1. Rating : 2 3 0 V; 5 0 H z ; 5 0 W a t t s2 . RPM : 9 5 0 0 rpm3. Amps : 9 A 4. Power : 1 H P5. Insulat ion : Class F6. Duty : S1 7. Protect ion : IP54
Indicating Lamps: The indicat ing lam ps are norm al LEDs w hich are present on t he contr o l panel .
These indicat ing lam ps indicate the undergoing process. Each process is l inked w ith an indicat ing lam p.
Glow ing of an indicat ing lam p denot es the correspondi ng undergoing pro cess. Total seven indicat ing
lamp s are used on the panel of W ater Cont ro l System fo r m onit or ing di f ferent processes.
A p u m p m o t o r
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CONTROL PHILOSOPHY
A PLC is to contro l an am usem ent park w ater r ide. The r ide is associated w i th a t ank of w ater
and splash a t our group. The r ide fu l l w i th t our grou p is sensed by cart det ect l imi t sw i tch. The
w ater t ank is associated w i th tw o solenoid operat ed va lve and correspond ing level sensor . The f i l l ing valve , accomp anied by level full sensor , is a t the t op end of the w ater tank w hereas the
out let valve , accom panied by level em pt y sensor , is a t the bo t t om o f the w ate r tank .
The pro cess start s in idle. The car t det ect l im i t swi t ch opens the f i l l ing va lve. After a delay of 30 seconds f rom the o pening of t he f i l l ing valve, the o ut le t va lve opens. W hen t he tan k is ful l ( level ful l sensor: healthy) t he f i l l ing valve closes. W hen t he tank is empt y ( level empt y sensor : heal thy) the ou t le t va lve c loses. After a delay of 10 seconds f rom the o pening of th e out le t va lve, a wat er je t opens. After a delay of 2 seconds, the water jet closes and the process returns to the idle
s tate.
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PROCESS FLOW CHART:
START
Idle : ON
Cart det ect l / sw : Low
Level f ul l sensor : Low
Filling valve :Close
Outlet valve : Close
W ater jet : Close
Level empt y
sensor : Heal thy
Is idle
ON ?
Is cartde tect l / sw :
High ?
Fil l ing valve: Open ?
A
Is level ful l
sensor:
High?
Filling valv e: Close
C
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A
LEVEL_EM PTY SENSOR: LOW
TIM ER (TON)_ T0 : START(fo r 30 sec)
TIM ER (TON)_T0 :
IS
TIM ER
(TON) _T0
OUTLET VALVE : OPEN
IS
LEVEL_EM PTY
SENSOR:
HIGH?
OU TLET VALVE : CLOSE
LEVEL_FU LL SENSOR :
LOW
TIM ER(TON)_ T1 :
START(for 10 secs)
TIM ER(TON)_ T1 : ENABLE
IS
TIM ER(TO
N)_T1 DN?
B
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B
W ATER JET : OPEN
TIM ER(TON)_ T2 :
START(fo r 2 secs)
TIM ER(T0N)_ T2 : ENABLE
IS
TIM ER(TO
N)_T2 DN?
W ATER JET :CLOSE
IS W ATER
JET :CLOSE
IDLE : ON
IS IDLE
ON ?
C END
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Gener a l a r r a nGement of cont r ol pa nel
FRON T V IEW
Notes:
All d imensions are in mi l l imet ers (mm ). Fabrication
The contro l box shal l be wa l l m ount ing type w i th w e lded construct ion .
M ater ia l of const ruct ionCubical body, m ount ing and gland plate: 2 mm . Cable entr ies shall be at bott om only.
Paint ingThe box shal l be degreased and der usted and ph osphate pro per ly by seven tank p rocess. Box
shall be painted by pow der coating.
Colour of f inish p aint Insid e and ou tsid e: SIEM ENS GREY [RAL 7032]
Gasket Neopr ene rubber gasket shal l be provided on do or and w herever necessary.
Degree of protect ion IP-54 [Indoor Dut y]
N a m e p la t e W hite engraved letter ing in b lack anodized alum inium .
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LEGEND DETAILS
T A GM A T ER IA L
D ESCRIPTIO N
R A N G E/
R AT I N GTY PE M A K E Q TY
U N I T
PRICE(RS.)
T O T A L
PRICE(RS.)
PLCProgrammable
Logic Control ler
I/ P: 10 no s.2 4 V D C
O /P: 8 nos.Relay typ e1440 VA
M icro Log ix1000
AllenBradley
12 2 0 0 0
PC-PLCCommunica t ion
RS-232, 9 PinConnector
1761-CBLPM O 2 Series C
AllenBradley
1
PSUPo w er Supp ly
U n i t
I /P: 100 -200 V D C,1.9A
200-240V A C,0 .8 A
O /P: 24V DC,4.5A
3872B O 3 3
M eanWe l l
1 500 500
CB 1M in iature
Circuit Breaker63A, BreakingCapacity 6 KA
TPN , Iso latortyp e, C curv e
H avel ls 1 800 80 0
C Con tacto r 10A , 230 V ACW i th (3 N O +
1 N C) Aux.contact
Telemechanique
1 400 400
A Ammeter0-100A;
Size: 72mm 2D irect reading,
Ana logAE 1 60 0 60 0
A SSAmmeter
Selecto r Sw it ch6 A
W i t h OFF 4Position
Kay cee 1 150 150
V Vo l tmeter0 -500 V
Size: 72mm 2 Analog AE 1 600 60 0
VSSVol tmeter
Selecto r Sw it ch6 A
W i t h OFF 4Posit ions
Kay cee 1 150 150
ITRFIsolat ion
TransformerI /P:110/220 V AC
O /P:110/ 220 V ACCTR: 1:1
5A , 50 -60 H zGup t aEngg.
1 750 750
CF 1-9 Co nt ro l Fuse 2AW ith basem oun t i ng
GEC 9 25 225
L1-L7
Panel IndicatingLamps
R&G - 2 no s.B,O ,Y-1 no each
23 0 V AC Fi lam ent typ e Siemens 7 155 108 5
FV,O V Solenoid Valve 24 V D C2 w ay ,
pneumat icRotecInst.
2 750 150 0
7/29/2019 Project Plc
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T A GM A T ER IA L
D ESCRIPTIO NR A N G E/R AT I N G
TYPE M AKEQ U A N
T I T Y
U N I T
PRICE
(RS.)
T O T A L
PRICE
(RS.)
MInduct ion
M o t o r
Ratin g :230 V;50Hz ;
5 0 W a t ts
RPM : 9 5 0 0 rpmAm : 9 A
Power : 1 H P
Insulat ion : Class F
Duty : S1
Protect ion : IP54
Slip Ring Chetak 1 90 0 90 0
LVR Louv er Size:150 m m 2 M esh Keym an 1 150 150
EXH F Exh aust Fan230V A C,
Size: 150mm 2Vent i la t ion O N Rexnord 1 600 600
CFL Lamp 23 0V AC, 12W Col o ur: W hite H avel ls 1 110 110
D LS Door L im i tSw itch
6 A Essen 1 120 120
TB Terminal Box 2.5 m m 2 Cl ip O n Type Elmex 60 8 480
Cu W i re2 . 5 m m 2,
Colo ur: RedPVC, in sulated ,
FRP FlexibleM escab 1 Coi l 100 0 100 0
Propex SheetH eigh t : 200m mW i d th : 2 0 0 m m
Thickness: 1.2mm
Transparent,Scratch Proof
SaintGobain
1 120 120
Hardwares(N ut , Bol ts,
W asher, Lug,
Ferrule, PVC,DIN Rai l ,G room et , N am ePlate, Earth in g
Stud , doo rknob, terminalend , plate etc)
Vari o us Size and Rating Reput edA s.
Reqd.1000 1000
Cont rol PanelH eigh t : 500m mW i d th : 5 0 0 m m
Thickness: 3 00 m m
W al l M o u n t in gIP 54
FabconTechnol
o gy1 3500 3500
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Bil l of ma t er ia l
SL.
N O.
M A T ER IA L
D ESCRIPTIO N
R A N G E/
R AT I N GTY PE M A K E Q TY
1.Programmable
Logic Control ler
I/ P: 10 no s.2 4 V D C
O /P: 8 nos.Relay typ e1440 VA
M icro Log ix1000
AllenBradley
1
2 .PC-PLC
Communica t ionRS-232, 9 Pin
Connector1761-CBL
PM O 2 Series CAllen
Bradley1
3 .Po w er Supp ly
U n i t
I /P: 100 -200V DC,1.9A
200-240V A C,0 .8 A
O /P: 24V DC,4.5A
3872B O 3 3
M eanWe l l
1
4 .M in iature
Circuit Breaker63A, BreakingCapacity 6 KA
TPN , Iso latortyp e, C curv e
H avel ls 1
5. Con tacto r 10A , 230 V ACW i th (3 N O +
1 N C) Aux.contact
Telemechanique
1
6. Ammeter0-100A;
Size: 72 m m 2D irect reading,
Ana logA E 1
7 .Ammeter
Selecto r Sw it ch6A
W i t h OFF 4Position
Kaycee 1
8. Vol tmeter0 -500 V
Size: 72 m m 2 An alog AE 1
9 .Vo l tmeter
Selecto r Sw it ch6A
W i t h OFF 4Posit ions
Kaycee 1
10 .Isolat ion
TransformerI /P:110/220 V AC
O /P:110/ 220 V ACCTR: 1:1
5A , 50 -60 H zGup t aEngg.
1
11. Co nt ro l Fuse 2AW ith basem oun t i ng
GEC 9
12 .
Panel IndicatingLamps
R&G - 2 no s.B,O ,Y-1 no each
23 0 V AC Fi lam ent typ e Siemens 7
13. So lenoid Valve 24 V D C 2 w ay ,pneumat ic
RotecInst.
2
14 .Induct ion
M o t o rSlip Ring Chetak 1
15. Louv er Size:150 m m 2 M esh Keyman 1
16 . Exh aust Fan230V A C,
Size: 150 m m 2Vent ilat ion O N Rexnord 1
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SL.
N O
.
M A T ER IA LD ESCRIPTIO N
R A N G E/R AT I N G
TYPE M AKEQ U A N
T I T Y
17 .
PanelI l luminat ing
Lamp230 V AC, 12W Colo ur: W hi te H avel ls 1
18 .Door L im i t
Sw itch6A Essen 1
19. Terminal Box 2.5 m m 2 Cl ip O n Type Elmex 60
20 . Cu W i re2 . 5 m m 2,
Colo ur: RedPVC, in sulated ,
FRP FlexibleM escab 1 Co il
21. Pro pex SheetH eigh t : 200m mW i d t h: 2 0 0 m m
Thickness: 1.2mm
Transparent,Scratch Proof
SaintGobain
1
22 .
Hardwares(N ut , Bol ts,
W asher, Lug,Ferrule, PVC,
DIN Rai l ,G room et , N am ePlate, Earth ing
Stud, d o orknob, terminalend , plate etc)
Vari o us Size and Rating Reput edA s.
Reqd.
23. Cont ro l PanelH eigh t : 500m mW i d t h: 5 0 0 m m
Thickness: 3 00 m m
W al l M o u n t in gIP 54
FabconTechnol
o gy1
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Sheet met a l ca l cul a t ion
Pane l He igh t : 500 m m . = 0 .5 m eter
W id th : 500 mm . = 0 .5 m e te rDepth : 300 m m . = 0 .3 m eter
M ount ing Pla te : 325 m m . (H) 400 m m . (W)
Sheet M etal constr uctio n : 2 m m . CRCA, TISCO
Sheet m eta l requ i red fo r cub ic le body o f the contr o l pane l= 2 [(0.5 0.5) + (0.5 0.3) + (0.3 0.5)] m
= 2 [0.25 + 0.15 + 0.15] m
= 2 0.55 m
= 1 .1 m
Sheet m eta l requ i red fo r moun t ing p la te o f the contro l pane l= 325 mm 400 mm= [0.325 0.4] m
= 0 .13 m
Tota l sheet m eta l requ i red fo r the contro l pane l : [1 .1 + 0 .13 ] m = 1 .23 m
Total w eight of the contro l panel : 1.23 m 16 Kg.[Since w eight of the 1 m m . CRCA : 8 Kg. / m = 19.68 Kg.
so weight of t he 2 m m . CRCA : 16 Kg. /m ]
Total cost for the contr o l panel : 19.68 Kg. @140/ -[Cost in cludes sheet m etal cost, transport at ion, fabr icat ion, paint ing, e lectr ic i ty, packing,
forw arding, labor charge etc.]
= 2755.20/ -
Say: 3500.00/-
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Cost a na l ysis
SL.
N O.
M A T ER IA L
D ESCRIPTIO N
R A N G E/
R A T I N GTY PE M A K E Q TY
U N I T
PRICE(RS.)
T O T A L
PRICE(RS.)
1.Programmable
Logic Control ler
I/ P: 10 n o s.2 4 V D C
O /P: 8 nos.Relay typ e1440 VA
M icro Log ix1000
Al lenBradley
1 2200 0 2200 0
2 .PC-PLC
Communica t ionRS-232, 9 Pin
Connector1761-CBL
PM O 2 Series CAl len
Bradley1
3 .Po w er Supp ly
U n i t
I /P: 100 -200V DC,1.9A
200-240V A C,0 .8 A
O / P: 24V DC,4 .5A
3872B O 3 3
M eanWe l l
1 500 500
4 .M in iature
Circuit Breaker63A, BreakingCapacity 6 KA
TPN , Iso latortyp e, C curve
H avel ls 1 80 0 80 0
5. Cont acto r 10A , 230 V ACW i th (3 N O +
1 N C) Aux.contact
Telemechanique
1 400 400
6. Ammeter0-100A;
Size: 72 m m 2D irect reading,
Ana logAE 1 60 0 60 0
7 .Ammeter
Selecto r Sw it ch6A
W i th OFF 4Position
Kay cee 1 150 150
8. Vol tmeter0 -500 V
Size: 72 m m 2 Analog AE 1 60 0 60 0
9 .Vo l tmeter
Selecto r Sw it ch6A
W i th OFF 4Posit ions
Kay cee 1 150 150
10.Isolat ion
TransformerI /P:110/ 22 0 V AC
O /P:110/ 220 V ACCTR: 1:1
5A , 50 -60 H zGup t aEngg.
1 750 750
11. Co nt ro l Fuse 2AW ith basem oun t i ng
GEC 9 25 225
12.
Panel IndicatingLamps
R&G - 2 n os.B,O ,Y-1 no each
23 0 V AC Fi lam ent typ e Siemens 7 155 108 5
13. So lenoid Valve 24 V D C 2 w ay ,pneumat ic
RotecInst.
2 750 1500
14.Induct ion
M o t o rSl ip Ring Chetak 1 90 0 90 0
15. Louv er Size:150 m m 2 M esh Keym an 1 150 150
16 . Exhau st Fan230V A C,
Size: 150mm 2Vent i la t ion O N Rexnord 1 600 600
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SL.
N O
.
M A T ER IA LD ESCRIPTIO N
R A N G E/R A T I N G
TYPE M AKEQ U A N
T I T Y
U N I T
PRICE
(RS.)
T O T A L
PRICE
(RS.)
17.
PanelI l luminat ing
Lamp23 0V AC, 12W Colo ur: W hite H avel ls 1 110 110
18.Doo r Lim i t
Sw itch6A Essen 1 120 120
19. Terminal Bo x 2.5 m m 2 Cl ip O n Type Elmex 60 8 480
20. Cu W i re2 . 5 m m 2,
Colo ur: RedPVC, insulated ,
FRP FlexibleM escab 1 Co i l 100 0 100 0
21. Pro p ex SheetHe ight : 200mmW i d th : 2 0 0 m m
Thickness: 1.2mm
Transparent,Scratch Proof
SaintGoba in
1 120 120
22 .
Hardwares(N ut , Bol ts,
W asher, Lug,Ferrule, PVC,
DIN Rai l ,G room et, N am ePlate, Eart hin g
Stud, do orknob, terminalend, p late etc)
Vari o us Size and Rating Reput edA s.
Reqd.1000 1000
23. Cont ro l PanelHe ight : 500mmW i d th : 5 0 0 m m
Thickness: 3 00 m m
W al l M o u n t in gIP 54
FabconTechnol
o gy1 3500 3500
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ConCl usion
A Program m able Logic Cont rol ler (PLC) is a hardw are invent ed t o replace the conve nt ional relay
log ic c ircu i ts for m achine and process cont ro l . Th is hardware can accept the real w or ld in put s
and can send the outputs command through i ts input /output modules. The PLC operates bysensing i ts inputs and depending upon the ir condi t ions, the outputs are act ivated. The user
w r i tes a program as per t he appl icat ion, usually v ia sof t w are, which w hen loaded and ru n in t he
PLC, pro duces th e d esired result s.
The appl icat ion of Programmable Logic Contro l ler is done in our pro ject on Water Contro l
System in a w ater am usem ent park. The u se of PLC m ade our system m ore accurate, re l iab le
and auto m ated. M oreover the w ir ing and fau lt det ect ion of the cont ro l system becam e easy
too . The use of PLC made ou r job s im pler , accurate and less hum an depende nt .
The applicat ion of SCADA (Supervisory Control and Data Acquisit ion) has also beenincorporated in o ur pr o ject . SCADA is a sof t w are approach to a cont ro l system that a l low s us to
m oni to r our system rem ote ly. Not o n ly th is , but i t a lso helps us detect i f t here is any funct ional
p rob lem in our system a t norm a l work ing cond i t ion .
Thus we f in d t hat W ater Cont rol System based on th e applicat ion o f PLC and SCADA is a m uch
m ore accurate, re liab le and autom ated t han the convent ional cont ro l system s. Not on ly i t has
made the system s imple in construct ion and t roubleshoot ing, but i t a lso a l lows us to set the
input var iables as desired through a PC control l ing the system. By using communication cards
we may transmit and receive signals through plc over a long distance. This al lows supervisionand cont ro l o f any contro l system rem ote ly.
W ith t he advancem ent in t he f ie lds of t echnology, the PLC technology is est im ated to be m ore
develope d and less costly. The use of PLC in ind ustr ies has becom e inevit able and expect ed t o
be more widespread in the near fu ture. And wi th use of PLC, t ime is not far away when
autom at ion w i l l be a re l ig ion in t he w or ld o f t echno logy .