vocational training PROJECT report

CONTENTS
Introduction System description Control Philosophy Process Flow chart Ladder Diagram SCADA Design AutoCAD Drawing General Arrangement PLC Control Circuit Single Line Diagram Power Circuit Legend Details

Bill of Material (B.O.M) Sheet Metal Calculation of Control Panel Project Costing Evaluation (Cost Analysis)

INTRODUCTION
The concerned project is based on Water Control System. In this project operations performed in an amusement park are logically designed in ladder logic. In this project the following software and hardware are used. Software: # Operating System # PLC Programming # SCADA Designing # Emulator # Communication Software # Communication Protocol # Communication Driver (with PLC) # Communication Driver (without PLC) # Drawing # Documentation # Utility Software : : : : : : : : : : : Microsoft Windows XP Professional Version 2002 Service Pack 3 RSLogix 500 English 7.00.00 (CPR 7) RSView 32 7.20.00 (CPR 7) RSLogix Emulate 500 RSLinx Classic 2.51.00 (CPR 7) DH-485; [ DH - Data High way ] AB _DF1 EMU-500 MS Paint Microsoft Office 2003, 2007 a) Rockwell Automation USB CIP Driver Package b) PDF Creator c) Adobe Reader 9.3 Intel Core 2 Duo CPU 3.06 GHz Intel Original Motherboard 2 GB DDR2 RAM, 320 GB SATA HDD 14 Colour TFT Monitor MicroLogix 1000, 1761-L16BWA 220V AC/24V DC Specification: 10 point input/6 point output Bus current draw: - 5V DC 0.04A 24V DC 0.105A Input range: - 4-20mA, 0-10V DC, Class2 Output range: - 4-20mA, 0-10V DC 1761-CBL-PM02, Series C

Hardware: # PC :

# PLC

# PC-> PLC Communication Port #Make [PLC & PC->PLC Communication Port] #Manufacturer

: :

Allen-Bradley Rockwell Automation

SyStem deScription
The main components used in Water Control System are as follows: 1. 2. 3. 4. 5. Limit switches Solenoid Valve Level Sensor Pump motor Indicating Lamps A mechanical limit switch is a

Limit switches:

electromechanical device which can be used to determine the physical position of equipment. The limit switch gives ON/OFF output that corresponds to position of equipment. It operates through pressure acting upon the switch and the state of the switch is determined accordingly. As seen from the given figure an extension on a valve shaft mechanically trips a limit switch as it moves from open to shut or shut to open. In Water Control System in water amusement park, limit switch is used to sense the position of cart (cart detect limit switch). The limit switch also senses whether the ride is full with the tour group. As the cart is over limit switch and the ride is full, limit switch changes state to ON state and the consequent action follows.

Solenoid valve: A solenoid valve is an electromechanical valve for use with liquid or gas. The valve is
controlled by an electric current through a solenoid. In the case of a two-port valve the flow is switched on or off and in the case of a three-port valve, the outflow is switched between the two outlet ports. Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to shut off, release, dose, distribute or mix fluids. A solenoid valve has two main parts: the solenoid and the valve. The solenoid converts electrical energy into mechanical energy which, in turn, opens or closes the valve mechanically. In Water Control System, the solenoid valve is used to control the outflow and inflow of water in the tank. A solenoid valve each at the inlet (filling valve) and exit (outlet valve) of tank is present and the level sensors senses water level and actuates the valve which in turn controls the flow of water from pipes both at inlet and outlet.

Level Sensor:

Level sensor is just an

electronic sensor that is used to sense level of a fluid. Level sensors detect the level of substances that flow, including liquids, slurries, granular materials, and powders. Fluids and fluidized solids flow to become essentially level in their containers (or other physical boundaries) because of gravity whereas most bulk solids pile at an angle of repose to a peak. The substance to be measured can be inside a container or can be in its natural form (e.g. a river or a lake). In this particular application, the level sensor is used to sense the liquid level in the water tank. A level sensor is present each at the top and the bottom of the tank. When the level full sensor detects the fluid, it actuates inlet valve to close and when the level empty sensor detects a particular minimum level of fluid in the tank, it actuates the outlet valve to close the outflow of water.

Pump motor: The pump motor is a device that is used to pump water. In our application the pump
motor is used to operate a water jet. The pump motor is for generation of water jet. Here we use a single phase induction motor for the generation of water jet. The specification of the motor used is as follows: 1. 2. 3. 4. 5. 6. 7. Rating : 230 V; 50 Hz ; 50 Watts RPM : 9500 rpm Amps :9A Power : 1 HP Insulation : Class F Duty : S1 Protection : IP54

A pump motor

Indicating Lamps: The indicating lamps are normal LEDs which are present on the control panel.
These indicating lamps indicate the undergoing process. Each process is linked with an indicating lamp. Glowing of an indicating lamp denotes the corresponding undergoing process. Total seven indicating lamps are used on the panel of Water Control System for monitoring different processes.

CONTROL PHILOSOPHY
A PLC is to control an amusement park water ride. The ride is associated with a tank of water and splash a tour group. The ride full with tour group is sensed by cart detect limit switch. The water tank is associated with two solenoid operated valve and corresponding level sensor. The filling valve, accompanied by level full sensor, is at the top end of the water tank whereas the outlet valve, accompanied by level empty sensor, is at the bottom of the water tank. The process starts in idle. The cart detect limit switch opens the filling valve. After a delay of 30 seconds from the opening of the filling valve, the outlet valve opens. When the tank is full (level full sensor: healthy) the filling valve closes. When the tank is empty (level empty sensor: healthy) the outlet valve closes. After a delay of 10 seconds from the opening of the outlet valve, a water jet opens. After a delay of 2 seconds, the water jet closes and the process returns to the idle state.

PROCESS FLOW CHART:

START

Idle : ON Cart detect l/sw : Low Level full sensor : Low Filling valve :Close Outlet valve : Close Water jet : Close Level empty sensor : Healthy

Is idle ON ?

Is cart detect l/sw: High ?

Filling valve: Open?

Is level full sensor: High?

A Filling valve: Close

A LEVEL_EMPTY SENSOR: LOW TIMER (TON)_T0 : START(for 30 sec)

TIMER (TON)_T0 :

IS TIMER (TON) _T0

OUTLET VALVE : OPEN

IS LEVEL_EMPTY SENSOR: HIGH? LEVEL_FULL SENSOR : LOW TIMER(TON)_T1 : START(for 10 secs) OUTLET VALVE : CLOSE TIMER(TON)_T1 : ENABLE

IS TIMER(TO N)_T1 DN?

WATER JET : OPEN

TIMER(TON)_T2 : START(for 2 secs)

TIMER(T0N)_T2 : ENABLE

IS TIMER(TO N)_T2 DN?

WATER JET :CLOSE

IS WATER JET :CLOSE

IDLE : ON

IS IDLE ON?

END

General arranGement of control panel

FRONT VIEW Notes:

All dimensions are in millimeters (mm). Fabrication The control box shall be wall mounting type with welded construction. Material of construction Cubical body, mounting and gland plate: 2 mm. Cable entries shall be at bottom only. Painting The box shall be degreased and derusted and phosphate properly by seven tank process. Box shall be painted by powder coating. Colour of finish paint Inside and outside: SIEMENS GREY [RAL 7032] Gasket Neoprene rubber gasket shall be provided on door and wherever necessary. Degree of protection IP-54 [Indoor Duty] Name plate White engraved lettering in black anodized aluminium.

LEGEND DETAILS
TAG MATERIAL DESCRIPTION RANGE/ RATING I/P: 10 nos. 24V DC O/P: 8 nos. Relay type 1440 VA RS-232, 9 Pin Connector I/P: 100-200V DC, 1.9A 200-240V AC, 0.8 A O/P: 24V DC, 4.5A 63A, Breaking Capacity 6KA 10A, 230V AC 0-100A; Size: 72mm2 6A 0-500 V Size: 72mm2 6A I/P:110/220 V AC O/P:110/220 V AC 2A TYPE MAKE QTY UNIT PRICE (RS.) TOTAL PRICE (RS.)

PLC

Programmable Logic Controller PC-PLC Communication

Micro Logix 1000 1761-CBL PMO2 Series C

Allen Bradley Allen Bradley

1 1

22000

PSU

Power Supply Unit

3872 BO33

Mean Well

500

500

CB 1 C A ASS V VSS ITRF CF 1-9

Miniature Circuit Breaker Contactor Ammeter Ammeter Selector Switch Voltmeter Voltmeter Selector Switch Isolation Transformer Control Fuse Panel Indicating Lamps R&G - 2 nos. B,O,Y-1 no each

TPN, Isolator type, C curve With (3 NO + 1 NC) Aux. contact Direct reading, Analog With OFF 4 Position Analog With OFF 4 Positions CTR: 1:1 5A, 50-60 Hz With base mounting Filament type

Havells Telemec hanique AE Kaycee AE Kaycee Gupta Engg. GEC

1 1 1 1 1 1 1 9

800 400 600 150 600 150 750 25

800 400 600 150 600 150 750 225

L1-L7

230 V AC

Siemens

155

1085

FV,OV

Solenoid Valve

24 V DC

2 way, pneumatic

Rotec Inst.

750

1500

TAG

MATERIAL DESCRIPTION

RANGE/ RATING Rating :230 V;50Hz ; 50 Watts RPM : 9500 rpm Am :9A Power : 1 HP Insulation : Class F Duty : S1 Protection : IP54 Size:150mm2 230V AC, Size: 150mm2 230V AC, 12W 6A 2.5 mm2 2.5 mm2, Colour: Red Height: 200mm Width: 200mm Thickness: 1.2mm

TYPE

MAKE

QUAN TITY

UNIT PRICE (RS.)

TOTAL PRICE (RS.)

Induction Motor

Slip Ring

Chetak

900

900

LVR EXHF CFL DLS TB

Louver Exhaust Fan Lamp Door Limit Switch Terminal Box Cu Wire Propex Sheet Hardwares (Nut, Bolts, Washer, Lug, Ferrule, PVC, DIN Rail, Groomet, Name Plate, Earthing Stud, door knob, terminal end, plate etc) Control Panel

Mesh Ventilation ON Colour: White

Keyman Rexnord Havells Essen

1 1 1 1 60 1 Coil 1

150 600 110 120 8 1000 120

150 600 110 120 480 1000 120

Clip On Type PVC, insulated, FRP Flexible Transparent, Scratch Proof

Elmex Mescab Saint Gobain

Various Size and Rating

Reputed

As. Reqd.

1000

1000

Height: 500mm Width: 500mm Thickness: 300mm

Wall Mounting IP 54

Fabcon Technol ogy

3500

3500

Bill of material
SL. NO . MATERIAL DESCRIPTION RANGE/ RATING I/P: 10 nos. 24V DC O/P: 8 nos. Relay type 1440 VA RS-232, 9 Pin Connector I/P: 100-200V DC, 1.9A 200-240V AC, 0.8 A O/P: 24V DC, 4.5A 63A, Breaking Capacity 6KA 10A, 230V AC 0-100A; Size: 72mm2 6A 0-500 V Size: 72mm2 6A I/P:110/220 V AC O/P:110/220 V AC 2A TYPE MAKE QTY

1.

Programmable Logic Controller PC-PLC Communication

Micro Logix 1000 1761-CBL PMO2 Series C

Allen Bradley Allen Bradley

1 1

2.

3.

Power Supply Unit

3872 BO33

Mean Well

4. 5. 6. 7. 8. 9. 10. 11.

Miniature Circuit Breaker Contactor Ammeter Ammeter Selector Switch Voltmeter Voltmeter Selector Switch Isolation Transformer Control Fuse Panel Indicating Lamps R&G - 2 nos. B,O,Y-1 no each Solenoid Valve Induction Motor Louver Exhaust Fan

TPN, Isolator type, C curve With (3 NO + 1 NC) Aux. contact Direct reading, Analog With OFF 4 Position Analog With OFF 4 Positions CTR: 1:1 5A, 50-60 Hz With base mounting Filament type 2 way, pneumatic Slip Ring

Havells Telemec hanique AE Kaycee AE Kaycee Gupta Engg. GEC

1 1 1 1 1 1 1 9

12.

230 V AC

Siemens Rotec Inst. Chetak Keyman Rexnord

13. 14. 15. 16.

24 V DC

2 1 1 1

Size:150mm2 230V AC, Size: 150mm2

Mesh Ventilation ON

SL. NO . 17.

MATERIAL DESCRIPTION Panel Illuminating Lamp Door Limit Switch Terminal Box Cu Wire Propex Sheet Hardwares (Nut, Bolts, Washer, Lug, Ferrule, PVC, DIN Rail, Groomet, Name Plate, Earthing Stud, door knob, terminal end, plate etc) Control Panel

RANGE/ RATING

TYPE

MAKE

QUAN TITY

230V AC, 12W

Colour: White

Havells

18. 19. 20. 21.

6A 2.5 mm2 2.5 mm2, Colour: Red Height: 200mm Width: 200mm Thickness: 1.2mm Clip On Type PVC, insulated, FRP Flexible Transparent, Scratch Proof

Essen Elmex Mescab Saint Gobain

1 60 1 Coil 1

22.

Various Size and Rating

Reputed

As. Reqd.

23.

Height: 500mm Width: 500mm Thickness: 300mm

Wall Mounting IP 54

Fabcon Technol ogy

Sheet metal calculation

Panel Height Width Depth Mounting Plate Sheet Metal construction : : : : : 500 mm. = 0.5 meter 500 mm. = 0.5 meter 300 mm. = 0.3 meter 325 mm. (H) 400 mm. (W) 2 mm. CRCA, TISCO

Sheet metal required for cubicle body of the control panel = 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 metal required for mounting plate of the control panel = 325 mm 400 mm = [0.325 0.4] m = 0.13 m Total sheet metal required for the control panel : [1.1 + 0.13] m = 1.23 m 1.23 m 16 Kg. = 19.68 Kg.

Total weight of the control panel [Since weight of the 1 mm. CRCA : 8 Kg. /m so weight of the 2 mm. CRCA : 16 Kg. /m]

Total cost for the control panel : 19.68 Kg. @140/[Cost includes sheet metal cost, transportation, fabrication, painting, electricity, packing, forwarding, labor charge etc.] = 2755.20/Say: 3500.00/-

Cost analysis
SL. NO . MATERIAL DESCRIPTION RANGE/ RATING I/P: 10 nos. 24V DC O/P: 8 nos. Relay type 1440 VA RS-232, 9 Pin Connector I/P: 100-200V DC, 1.9A 200-240V AC, 0.8 A O/P: 24V DC, 4.5A 63A, Breaking Capacity 6KA 10A, 230V AC 0-100A; Size: 72mm2 6A 0-500 V Size: 72mm2 6A I/P:110/220 V AC O/P:110/220 V AC 2A TYPE MAKE QTY UNIT PRICE (RS.) TOTAL PRICE (RS.)

1.

Programmable Logic Controller PC-PLC Communication

Micro Logix 1000 1761-CBL PMO2 Series C

Allen Bradley Allen Bradley

1 1

22000

22000

2.

3.

Power Supply Unit

3872 BO33

Mean Well

500

500

4. 5. 6. 7. 8. 9. 10. 11.

Miniature Circuit Breaker Contactor Ammeter Ammeter Selector Switch Voltmeter Voltmeter Selector Switch Isolation Transformer Control Fuse Panel Indicating Lamps R&G - 2 nos. B,O,Y-1 no each Solenoid Valve Induction Motor Louver Exhaust Fan

TPN, Isolator type, C curve With (3 NO + 1 NC) Aux. contact Direct reading, Analog With OFF 4 Position Analog With OFF 4 Positions CTR: 1:1 5A, 50-60 Hz With base mounting Filament type 2 way, pneumatic Slip Ring

Havells Telemec hanique AE Kaycee AE Kaycee Gupta Engg. GEC

1 1 1 1 1 1 1 9

800 400 600 150 600 150 750 25

800 400 600 150 600 150 750 225

12.

230 V AC

Siemens Rotec Inst. Chetak Keyman Rexnord

155

1085

13. 14. 15. 16.

24 V DC

2 1 1 1

750 900 150 600

1500 900 150 600

Size:150mm2 230V AC, Size: 150mm2

Mesh Ventilation ON

SL. NO . 17.

MATERIAL DESCRIPTION Panel Illuminating Lamp Door Limit Switch Terminal Box Cu Wire Propex Sheet Hardwares (Nut, Bolts, Washer, Lug, Ferrule, PVC, DIN Rail, Groomet, Name Plate, Earthing Stud, door knob, terminal end, plate etc) Control Panel

RANGE/ RATING

TYPE

MAKE

QUAN TITY

UNIT PRICE (RS.) 110

TOTAL PRICE (RS.) 110

230V AC, 12W

Colour: White

Havells

18. 19. 20. 21.

6A 2.5 mm2 2.5 mm2, Colour: Red Height: 200mm Width: 200mm Thickness: 1.2mm Clip On Type PVC, insulated, FRP Flexible Transparent, Scratch Proof

Essen Elmex Mescab Saint Gobain

1 60 1 Coil 1

120 8 1000 120

120 480 1000 120

22.

Various Size and Rating

Reputed

As. Reqd.

1000

1000

23.

Height: 500mm Width: 500mm Thickness: 300mm

Wall Mounting IP 54

Fabcon Technol ogy

3500

3500

ConClusion
A Programmable Logic Controller (PLC) is a hardware invented to replace the conventional relay logic circuits for machine and process control. This hardware can accept the real world inputs and can send the outputs command through its input/output modules. The PLC operates by sensing its inputs and depending upon their conditions, the outputs are activated. The user writes a program as per the application, usually via software, which when loaded and run in the PLC, produces the desired results. The application of Programmable Logic Controller is done in our project on Water Control System in a water amusement park. The use of PLC made our system more accurate, reliable and automated. Moreover the wiring and fault detection of the control system became easy too. The use of PLC made our job simpler, accurate and less human dependent. The application of SCADA (Supervisory Control and Data Acquisition) has also been incorporated in our project. SCADA is a software approach to a control system that allows us to monitor our system remotely. Not only this, but it also helps us detect if there is any functional problem in our system at normal working condition. Thus we find that Water Control System based on the application of PLC and SCADA is a much more accurate, reliable and automated than the conventional control systems. Not only it has made the system simple in construction and troubleshooting, but it also allows us to set the input variables as desired through a PC controlling the system. By using communication cards we may transmit and receive signals through plc over a long distance. This allows supervision and control of any control system remotely. With the advancement in the fields of technology, the PLC technology is estimated to be more developed and less costly. The use of PLC in industries has become inevitable and expected to be more widespread in the near future. And with use of PLC, time is not far away when automation will be a religion in the world of technology.