Project Plc

7/29/2019 Project Plc

1/18

v oca t i ona l t r a in ing PROJECTr epo r t


2/18

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)


3/18

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


4/18

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 .


5/18

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


6/18

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.


7/18

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


8/18

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


9/18

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


10/18

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 .


11/18

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


12/18

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


13/18

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


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


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


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


1

11. Co nt ro l Fuse 2AW ith basem oun t i ng

GEC 9

12 .


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


14/18

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


SaintGobain

1

22 .


W asher, Lug,Ferrule, PVC,

DIN Rai l ,G room et , N am ePlate, Earth ing

Stud, d o orknob, terminalend , plate etc)


Reqd.

23. Cont ro l PanelH eigh t : 500m mW i d t h: 5 0 0 m m

Thickness: 3 00 m m


FabconTechnol

o gy1


15/18

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/-


16/18

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


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


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


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


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


1 750 750

11. Co nt ro l Fuse 2AW ith basem oun t i ng

GEC 9 25 225

12.


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


17/18

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


SaintGoba in

1 120 120

22 .


W asher, Lug,Ferrule, PVC,

DIN Rai l ,G room et, N am ePlate, Eart hin g

Stud, do orknob, terminalend, p late etc)


Reqd.1000 1000

23. Cont ro l PanelHe ight : 500mmW i d th : 5 0 0 m m

Thickness: 3 00 m m


FabconTechnol

o gy1 3500 3500


18/18

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 .

Project Plc

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