Summer Training Report

At Hindalco Industries Limited Renokoot U.P.

on Instrumentation in fabrication Plant

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Submitted By : UNDEFINED ECE 7th Sem PASSION SEAMLESSNESS SPEED

Table of Contents Hindalco Industries Limited Overview Fabrication / Instrument Department Remelt Shop Extrusion Press Rolling Mill Chemical / P. T. Lab Product Range PLC Basics PLC Simple ProgrammingINTEGRITY COMMITTMENT PASSION SEAMLESSNESS SPEED

Hindalco - An Overview Hindalco Industries Limited is the flagship company of one of Indias leading business houses, the Aditya Birla Group. The group has been in operations spanning over 5 decades with global presence. A powerhouse in non-ferrous metals. Hindalco has 2 business activities Aluminium and Copper. Aditya Birla Group Incorporated in 1958. Hindalco commenced production of Aluminium in 1962 at Renukoot, Uttar Pradesh with an initial capacity of 20,000 MTPA of aluminium metal. In 2000 Hindalco acquired a majority stake in Indian Aluminium Company Ltd.INTEGRITY COMMITTMENT PASSION SEAMLESSNESS SPEED

HINDALCO - INTEGRATED OPERATIONSRaw Materials Raw Materials ( Bauxite )

Co- GenerationPower By Renusagar Power Plant

Caustic Soda Aluminium fluoride

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Instrument Department Instrumentation Plant is R & D and maintenance Department of Hindalco. Function of Instrument Department is to maintain the Electronic equipment which is used in fabrication Plant and also find the easiest method to do it.

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Remelt Shop

The are various types of shop comes under the Remelt shop like Properzi, Cooling Tower R & D.INTEGRITY COMMITTMENT PASSION SEAMLESSNESS SPEED

Extrusion Press

Extrusion Press is system that reduces the Diameter of various types of Billet( Solid Aluminium Rod).

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Rolling Mill

Rolling mill is the System which reduces the thickness of the materials and produces thin sheets from slabs.

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Chemical Lab

Chemical Laboratory Finds the various types of alloy combinations and the property of the aluminium after mixing the alloy.INTEGRITY COMMITTMENT PASSION SEAMLESSNESS SPEED

P. T. Laboratory

P.T. Lab measures the Physical parameter of aluminium and find the various property of aluminium, like breaking strength, tensile strength etc.INTEGRITY COMMITTMENT PASSION SEAMLESSNESS SPEED

Hindalco Product Range

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PLC Basics : DescriptionThis Presentation introduces the basic hardware and software components of a Programmable Controller (PLC). It details the architecture and basic instruction set common to all PLCs. Basic programming techniques and logic designs are covered. This Presentation describes the operating features of the PLC, the advantages of the PLC over hard-wired control systems, practical applications, troubleshooting and maintenance of PLCs.INTEGRITY COMMITTMENT PASSION SEAMLESSNESS SPEED

Advantages of PLCs

Advantages of PLCs Less wiring. Wiring between devices and relay contacts are done in the PLC program. Easier and faster to make changes. Trouble shooting aids make programming easier and reduce downtime. Reliable components make these likely to operate for years before failure.

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Historical Background

The Hydramatic Division of the General Motors Corporation specified the design criteria for the first programmable controller in 1968. Their primary goal To eliminate the high costs associated with inflexible, relay-controlled systems.

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Programmable Logic Controllers( Definition according to NEMA standard ICS3-1978)

A digitally operating electronic apparatus which uses a programming memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog modules, various types of machines or process.

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Leading Brands Of PLCAMERICAN 1. 2. 3. 4. EUROPEAN 1. 2. 3. 4. JAPANESE 1. 2. 3. 4. Allen Bradley Gould Modicon Texas Instruments General Electric Siemens Klockner & Mouller Festo Telemechanique Toshiba Omron Fanuc Mitsubishi

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Areas of Application

Manufacturing / Machining Food / Beverage Metals Power Mining

Petrochemical / Chemical

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PLC Size- it covers units with up to 128 I/Os and memories up to 2 Kbytes. - these PLCs are capable of providing simple to advance levels or machine controls. 2. MEDIUM - have up to 2048 I/Os and memories up to 32 Kbytes. 3. LARGE - the most sophisticated units of the PLC family. They have up to 8192 I/Os and memories up to 750 Kbytes. - can control individual production processes or entire plant. 1. SMALL

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Tank Used to Mix Two Liquids

MOTOR

AFS

FLOAT SWITCH

SOLENOIDS

B

SOLENOID

CTIMER

1 -MINUTE

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Major Components of a Common PLC

POWER SUPPLY

From SENSORSPushbuttons, contacts, limit switches, etc.

I M N O P D U U T L E

PROCESSOR

O U T P U T

M O D U L E

To OUTPUTSolenoids, contactors, alarms etc.

PROGRAMMING DEVICE

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Major Components of a Common PLCPOWER SUPPLY I/O MODULES PROCESSOR PROGRAMMING DEVICE

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I/O ModuleDC INPUT MODULEUSE TO DROP THE VOLTAGE TO LOGIC LEVELIS NEEDED TO: Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise

FROM INPUT DEVICE

Current Limiting Resistor

OPTOISOLATOR

Buffer, Filter, hysteresis Circuits

TO PROCESSOR

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I/O ModuleDC / AC OUTPUT MODULEIS NEEDED TO: Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise

FROM PROCESSOR

TTL Circuits

OPTOISOLATOR

Amplifier RELAY TRIAC RESISTOR

TO OUTPUT DEVICE

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INPUT / OUTPUTINPUTS OUTPUTS

MOTOR

CONTACTORPUSHBUTTONS

PLCLAMP

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PLC ConnectionCONTACTOR

L2

L1

N.O

MOTOR C

L2 L1FIELD WIRING

SOLENOID VALVES LAMP BUZZER

OUTPUT MODULE WIRING L1

O:4

L2

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Discrete InputA discrete input also referred as digital input is an input that is either ON or OFF are connected to the PLC digital input. In the ON condition it is referred to as logic 1 or a logic high and in the OFF condition maybe referred to as logic o or logic low.Normally Open Pushbutton Normally Closed Pushbutton

Normally Open switchNormally Closed switch Normally Open contact Normally closed contactINTEGRITY COMMITTMENT PASSION SEAMLESSNESS SPEED

IN

OFF Logic 0

PLC Input Module24 V dc

IN

OFF Logic 1

PLC Input Module24 V dc

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Analog InputAn analog input is an input signal that has a continuous signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA or 0 to 10V. Below, a level transmitter monitors the level of liquid in the tank. Depending on the level Tx, the signal to the PLC can either increase or decrease as the level increases or decreases.Level TransmitterIN

Tank

PLC Analog Input Module

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Digital OutputA Digital output is either in an ON or OFF condition. Solenoids, contactors coils, lamps are example of devices connected to the Discrete or digital outputs. Below, the lamp can be turned ON or OFF by the PLC output it is connected to.OUT

PLC

LampDigital Output Module

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Analog OutputAn analog output is an output signal that has a continuous signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V.Electric to pneumatic transducerOUT

E

PLC Analog Output Module

0 to 10V

P

Supply air

Pneumatic control valve

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Basic Function of PLCWhile the PLC is running, the scanning process includes the following four phases, which are repeated continuously as individual cycles of operation:PHASE 1

Read Inputs ScanPHASE 2

Program ExecutionPHASE 3

Diagnostics/ CommPHASE 4

Output Scan

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Selecting a PLC

Criteria Number of logical inputs and outputs. Memory Number of special I/O modules Scan Time Communications Software

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PLC Programming SoftwareExamples of PLC Programming Software:1. Allen-Bradley Rockwell Software RSLogix500 2. Modicon - Modsoft 3. Omron - Syswin 4. GE-Fanuc Series 6 LogicMaster6 5. Square D- PowerLogic 6. Texas Instruments Simatic 6. Telemecanique Modicon TSX Micro

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PROGRAMMING

Normally Open (NO)

Normally Closed (NC)

Power flows through these contacts when they are closed. The normally open (NO) is true when the input or output status bit controlling the contact is 1. The normally closed (NC) is true when the input or output status bit controlling the contact is 0.

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Coils

Coils represent relays that are energized when power flows to them. When a coil is energized it causes a corresponding output to turn on by changing the state of the status bit controlling the output to 1. That same output status bit maybe used to control normally open or normally closed contact anywhere in the program.

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AND OPERATIONARung

B

C

Each rung or network on a ladder program represents a logic operation. In the rung above, both inputs A and B must be true (1) in order for the output C to be true (1).

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OR OPERATIONARung B C

In the rung above, it can be seen that either input A or B is be true (1), or both are true, then the output C is true (1).

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NOT OPERATIONARung C

In the rung above, it can be seen that if input A is be true (1), then the output C is true (0) or when A is (0), output C is 1.

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References

Hindalco Works Library www.hindalco.com www.adityabirla.com en.wikipedia.org/wiki/Aditya_Birla_Group en.wikipedia.org/wiki/Hindalco_Industries en.wikipedia.org/wiki/Programmable_logic_controller en.wikipedia.org/wiki/PLC program-plc.blogspot.com

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Thank You !

Thank You For Giving Your Valuable Time !

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