CONCERNED PROJECT REPORT ON HYPER GLASS

CLEANER

NAME: RIK MITRA

COURSE CODE: IA 05
COURSE PLAN: ENHANCED COMPOSITE PLAN
REGISTRATION NO.: QA217900
CONDUCTED BY: IIATCA
 CONTENTS

SUBJECTS PAGE NO.

INTRODUCTION
PLC DESCRIPTION
SYSTEM DESCRIPTION
SYSTEM COMPONENTS
CONTROL PHILOSOPHY
PROCESS FLOW CHART
LADDER DIAGRAM
SCADA DIAGRAM
GA OF THE PANEL
LEGEND DETAILS
SINGLE LINE DIAGRAM
POWER CIRCUIT
CONTROL CIRCUIT
CONTROL CIRCUIT OF LED
UTILITY CIRCUIT
BILL OF MATERIALS
SHEET METAL CALCULATION
COST ANALYSIS
CONCLUSION
 ACKNOWLEDGEMENT
I would like to thank IIATCA for providing such a platform to learn
“INDUSTRIAL AUTOMATION” with a vast knowledge of PLCs, DCSs and
Drives. I would pay my gratitude to Mr. Swarup Bose and Mr. Arnab Biswas.
They continuously encouraged ourselves from beginning to end of my course
which helped me to grasp the concepts of Process Control, Electrical and
Instrumentation Technology. Last but not the least I would like to show my
regards to IIATCA for providing me such a career changing opportunity.
 INTRODUCTION
This project is based on the operation of a Hyper Glass Cleaner. There is various
process involved in this plant that are performed serially, one after another. The total
operation is designed using "Ladder Logic".
Software Used:
Operating system: Microsoft Windows 8.1
PLC Programming tool: SIMATIC STEP 7 v5.4 + sp3
SCADA Designing: SIMATIC WinCC v5.1
Simulation Software: SIMATIC S7-PLCSIM v5.2 + sp2
Comm. Protocol: PROFIBUS
Comm. Driver: MPI Adapter
Drawing: AutoCAD 2008
Documentation: Microsoft Office 2007
Other Software's: PDF Creator
Adobe Reader 9.3
Hardware Used:
Laptop: Specification: 1. Display: 15.50 inch
2. Display Resolution: 1366*768 pixels
3. RAM: 4GB
4. Processor: Intel core i3
5. Bit: 64 Bits
PLC: SIMATIC S7-300; CPU 312; 312-1AE14-0AB0
External DI/DO Module * 2: SM 323 DI8/DO8 x DC 24V; 6ES7 323-1BH01-0AA0
External DO Module: SM 323 DO8 x DC 24V/ 0.5A; 6ES7 323-8BF80-0AB0
PC to PLC Comm. Port: MPI Adapter
Note: All the above-mentioned hardware's are Siemens make.
 PLC DESCRIPTION
ARCHITECTURE OF SIEMENS
PS
CPU
IM
DI8/DO8
DI8/DO8
DO8
…..
…..
1. PS (power supply)
Slot.1 is always reserved for PS INPUT 230volt/120volt ac, single phase 50 to 60
Hertz, 24-volt dc, Output= 24-volt de external, current 2 amps, 5 amp
2. CPU (Central Processing Unit)
Slots no. 2 is always reserved memory (Load memory, work memory, system
memory)
✓ Load memory: this memory is used to store the user program
Capacity. -> 64 kb to 256 kb
✓ Work memory: this is the execution memory of Siemens plc.
✓ System memory: called in-built memory used to store the memory of
predefined files. Like Input image table, Timer, Counter, Diagnostic buffer.
3. DI/DO MODULES
It contains two DI8/DO8 modules and one DO8 modules.
4. Communications Protocols
MPI - It stand for multi-point interface.
Nodes-32 support
Network - 187.5kbps
Port-Rs 485
PROFIBUS (Process Field Bus)
• Baud rate will go up to 12mbps
• Maximum node can be connected up to 126
 SYSTEM DESCRIPTION
Three ingredients (City water, QR ingredient, and KM ingredient) are added in
specified amounts by weight to the Mixing Tank. After all the ingredients have
added to the mixing Tank, the Mixer is blended by running the Agitator for a
given time. When the blending time is completed, the finished product is pumped
to the Filling Lines for bottling and final Packing. The main objective of this
project is to apply plc to design automatic mixing system. To drive the main
objective there are several supporting goals need to be achieved as listed below:

 To design a closed-loop system which can control adding and mixing the
ingredients which are used.

 To make sure that valve does open at the right time to insure delivery of
the ingredients to the mixer.

 Limit switches which ensure that the valves do opens or closes.

 To maintain an automatically and continuous flow rate into the filling

lines.
 SYSTEM COMPONENTS
1. Valves:
AV-CW: Supplies city water to the mixing tank.
AV-QR: Supplies QR ingredient to the mixing tank.
AV-KM: Supplies KM ingredient to the mixing tank.
AV-MT: Supplies the finished product to the filling lines.
2. Limit Switches:
LS-CW1: Indicates when valve AV-CW is closed.
LS-CW2: Indicates when valve AV-CW is open.
LS-QR1: Indicates when valve AV-QR is closed.
LS-QR2: Indicates when valve AV-QR is open.
LS-KM1: Indicates when valve AV-KM is closed.
LS-KM2: Indicates when valve AV-KM is open.
LS-MT1: Indicates when valve AV-MT is closed.
LS-MT2: Indicates when valve AV-MT is open.
3. Pumps:
Pump-QR: Pumps ingredient QR to the mixing tank.
Pump-KM: Pumps ingredient KM to the mixing tank.
Pump-MT: Pumps ingredient MT from the mixing tank.
4 Motor:
Agitator MTR-MTA: Blends the ingredient in the mixing tank.
5 Operator Panel Components:
1) System ready light PL1: Indicates the system is ready for Batch.
2) System fault pilot light PL2: Indicates the system has a fault.
3) Start batch pushbutton switch PB1: Start a new batch.
4) Stop batch push button switch PB2: Stop the batching process.
5) Adding water light PL3: Indicates adding water to the mixing tank.
6) Adding QR light PL4: Indicates adding QR to the mixing tank.
7) Adding KM light PL5: Indicates adding KM to the mixing tank.
8) Blending pilot light PL6: Indicates blending the ingredients.
9) Pumping to lines light PL7: Indicates pumping the ingredients.
10) E-stop Pushbutton PB3: Immediately stops the entire system.
 CONTROL PHILOSOPHY
• In the Tea Process Automation, tea leaves are pulled to weathering chamber to
get totally dry state. Tea leaves, just collected from tea-garden, consist some
amount of water moisture. To eliminate this small amount of water moisture
weathering process is required. Weathering process takes some time to make the
tea leaves dry from its dripping condition.

• After finishing the weathering process, tea leaves go to rolling chamber rapidly
for getting separate state one from another. In this section one tea leaves becomes
separate from another leaf. Rolling process takes time to separate tea leaves one
from another.

• After finishing the rolling process, tea leaves go to CFM (Continuous

Fermenting Machine). Fermenting process of total amount of tea leaves is done
here. After completion of fermenting process tea leaves get semi-liquid form.
This process also takes some time same as other.

• After completion of fermenting process semi-liquid formed tea leaves are fed to
MHC (Material Handling Conveyor). The feeding is done taking care of the time
of exposure of the leaves of the conveyor to allow various bio-chemical
processing (TR/TF) of leaves. We are enclosing a chart of the time the leaves are
exposed with respect to the ambient temperature. Now the end-user wants an
open loop control system (since feedback is not dependent on the output) where
the feeding to the dryer will be done automatically with response to the ambient
temp. Since the bio-chemical processing is controlled based on the physical
observation by the experienced operator, the end-user wants a provision to vary
i.e. feed a desired speed to the conveyor speed control system at any particular
temperature other than the default value (i.e. factory set values of the control
system programmed in accordance to the enclosed chart provided by the end
user) of the control system, so that the exposure time of the team leaves can be
varied according to the ambient temperature.
 LEGEND
SL Tag Material Range/Rating Make Quantity
No. Description Type
1. SFU TPN SFU >=120A L&T/HAVELS 1
V Volt Meter 0-500 V AC Analog MECO 1
2.
Type
VSS Volt Meter Selector 6A KAYCEE 1
3. Switch
A Ammeter 0-150 A AC Analog MECO 1
4.
Type
ASS Ammeter Selector 6A KAYCEE 1
5. Switch
6. CF Control Fuse 2A each SIEMENS 10
CT Current Transformer 150:50 5 VA burden KAPPA 3
7.
L1, L2, Indicating Lamps 230 V AC SIEMENS 37
8. L3....., LED 24 V DC
L37
ITRF Isolating Ratio 1:1, 10A GUPTA 1
9. Transformer I/P: 230 V AC ENGINEERING
O/P: 230 V AC
PSU Power Supply Unit I/P: 230 V AC SIEMENS 1
10. O/P: 24 V DC
5A
CB1, DP MCB 10A, 415V L&T/HAVELS 3
11. CB2, CB3 C Curve

PLC Programmable MICRO LOGIX 1200 ROCKWELL 1

12.
Logic Controller
DI, AO External Digital and 24 V DC, 0.5A & ROCKWELL 2
Analog Module 10mA
(DO8, 2AI/2A0)
13.

PF Power Fuse [2x Full load current GEC 33

(up to 5 H.P motor)
14. 3x Full load current
(above 5 H.P motor)]
16A, Thermal Fuse
 S2, S3 ,…, ICTP Switch [2x Full load current L&T/HAVELS 11
S12 (up to 5 H.P motor)
3x Full load current
15. (above 5 H.P motor)]
Breaking Current
16A

R1, R2, Control Relay 230 V AC, 5A, 2 PLA 11

16.
…, R11 C/O (2 NO+2 NC)
VFD Variable 415V, 50Hz DAN FOSS 1
17. Frequency Drive

CB4, CB5, TPN MCB 16 A C Curve L&T/HAVELS 11

18. …, CB14

C1, C2, TP Contactors 230 V AC, 12A, AC- TELEMEC 10

19.
…, C15 3 duty HANIQUE
TB Terminal Block 2/2.5 mm2 Clip on JIGO Bulk Quantity
20.
type
BUSBAR Busbar 3 PH, 23mm x 4mm ELECTRO As per
Electrolytic grade ALLIED requirement
21.
N: 23mm x 2mm SOLUTION

START, Push buttons with 1 NO (GREEN) SIEMENS 3

22. STOP, E- elements 2 NC (RED)
STOP
EXHF Exhaust Fan 230 V AC, SAINT GOBAIN 2
23.
150mm2
SW-SOC Switch Socket 230 V AC, ROTEC 1
24. Board 5/15 A INSTRUMENT

LVR Louver 150 mm2 mesh type KEYMAN 2

25.
CFL Compact 230 V AC, 10 W BAJAJ 1
26. Fluorescent Lamp WHITE

OTHERS Hardware’s (PVC Various ISHANI As per

channel, DIN requirement
Rail, Lifting
Hook, Lock
Screw, Nuts &
27. Bolts, Lugs,
Cable Tie, AV
Pad, Rubber
Gasket, Grommet
etc.)
Control panel H: 2000m ELECTRO 1
28. W: 1000m ALLIED
D: 500m SOLUTION
 BILL OF MATERIALS(BOM)
SL Material Range/Rating Make Quantity
No. Description Type
1. TPN SFU >=120A L&T/HAVELS 1
Volt Meter 0-500 V AC Analog MECO 1
2. Type
Volt Meter Selector 6A KAYCEE 1
3. Switch
Ammeter 0-150 A AC Analog MECO 1
4. Type
Ammeter Selector 6A KAYCEE 1
5. Switch
6. Control Fuse 2A each SIEMENS 10
Current Transformer 150:50 5 VA burden KAPPA 3
7.
Indicating Lamps LED 230 V AC SIEMENS 37
8. 24 V DC

Isolating Transformer Ratio 1:1, 10A GUPTA 1

9. I/P: 230 V AC ENGINEERING
O/P: 230 V AC
Power Supply Unit I/P: 230 V AC SIEMENS 1
10. O/P: 24 V DC
5A
DP MCB 10A, 415V L&T/HAVELS 3
11. C Curve

Programmable Logic MICRO LOGIX 1200 ROCKWELL 1

12. Controller
External Digital and 24 V DC, 0.5A & 10mA ROCKWELL 2
Analog Module (DO8, 2AI/2A0)

13.

Power Fuse [2x Full load current (up GEC 33

to 5 H.P motor) 3x Full
load current (above 5 H.P
14.
motor)] 16A, Thermal
Fuse
 ICTP Switch [2x Full load current (up L&T/HAVELS 11
to 5 H.P motor) 3x Full
load current (above 5
15. H.P motor)] Breaking
Current 16A
 Control Relay 230 V AC, 5A, 2 C/O (2 PLA 11
16.
NO+2 NC)
Variable Frequency 415V, 50Hz DAN FOSS 1
17. Drive

TPN MCB 16 A C Curve L&T/HAVELS 11

18.

TP Contactors 230 V AC, 12A, AC-3 TELEMEC 10

19.
duty HANIQUE
Terminal Block 2/2.5 mm2 Clip on type JIGO Bulk Quantity
20.
Busbar 3 PH, 23mm x 4mm ELECTRO ALLIED As per requirement
Electrolytic grade SOLUTION
21.
N: 23mm x 2mm

Push buttons with 1 NO (GREEN) SIEMENS 3

22. elements 2 NC (RED)

Exhaust Fan 230 V AC, SAINT GOBAIN 2

23.
150mm2
Switch Socket Board 230 V AC, ROTEC 1
24. 5/15 A INSTRUMENT

Louver 150 mm2 mesh type KEYMAN 2

25.
Compact 230 V AC, 10 W BAJAJ 1
26. Fluorescent Lamp WHITE

Hardware’s (PVC Various ISHANI As per requirement

channel, DIN Rail,
Lifting Hook, Lock
Screw, Nuts &
Bolts, Lugs, Cable
27. Tie, AV Pad,
Rubber Gasket,
Grommet etc.)

Control panel H: 2000m ELECTRO ALLIED 1

28. W: 1000m SOLUTION
D: 500m
 SHEET METAL CALCULATION
The Purpose of metal sheet calculation is to find out the total cost of the panel
construction.
Panel Dimension:
Height= 2000mm = 2m
Width= 1000mm = 1m
Depth= 500mm = 0.5m
Area of the cubical body = 2(2*1+1*0.5+0.5*2) = 2*3.5=7 sq.m
Weight of the 2mm thick CRCA sheet = 16Kg/sq.m
Total Weight = 16*7 = 112Kg/sq.m
Mounting Plate:
Length=1300m = 1.3m
Width=800mm = 0.8mm
Area of the mounting plate = 1.3*0.8 = 1.04 sq.m.
Weight of the 2.5mm thick CRCA = 20Kg/sq.m
Total Weight=20*1.04 = 20.8kg/sq.m
Channel Base:
Length = 1500mm = 1.5m
Width = 700mm = 0.7m
Thickness = 6mm = 0.006m
Area of the channel base = 1.5*0.7 = 1.05 sq.m
Weight of the 6mm thick CRCA sheet = 48Kg/sq.m
Total Weight of the Channel base = 48*1.05 = 50.4kg/sq.m

Total Weight of the Panel = 112+20.8+50.4 = 183.2 kg/sq.mi

Cost/Kg of the CRCA sheet = 193 INR
Total Cost of the CRCA sheet = 183.2*193 = 33,357.6INR
 COST ANALYSIS
SL Material Make Quantity Cost/Unit Overall
No. Description Cost
1. TPN SFU L&T/HAVELS 1 1000 1000
Volt Meter MECO 1 700 700
2.
Volt Meter Selector KAYCEE 1 200 200
3. Switch
Ammeter MECO 1 700 700
4.
Ammeter Selector KAYCEE 1 200 200
5. Switch
6. Control Fuse SIEMENS 10 500 5000
Current Transformer KAPPA 3 25 75
7.
Indicating Lamps SIEMENS 37 150 5550
8. LED

Isolating Transformer GUPTA 1 5000 5000

9. ENGINEERING

Power Supply Unit SIEMENS 1 600 600

10.

DP MCB L&T/HAVELS 3 2000 6000

11.

Programmable Logic ROCKWELL 1 40000 40000

12. Controller
External Digital and ROCKWELL 2 7000+8000 15000
Analog Module

13.

Power Fuse GEC 33 200 6600

14.
 ICTP Switch L&T/HAVELS 11 950 10450

15.

Control Relay PLA 11 200 2200

16.
Variable DAN FOSS 1 20000 20000
17. Frequency Drive

TPN MCB L&T/HAVELS 11 750 8250

18.

TP Contactors TELEMEC 10 700 7000

19.
HANIQUE
Terminal Block JIGO Bulk Quantity 2000 2000
20.
Busbar ELECTRO As per 10000 10000
ALLIED requirement
21.
SOLUTION

Push buttons with SIEMENS 3 280 840

22. elements

Exhaust Fan SAINT GOBAIN 2 300 600

23.
Switch Socket ROTEC 1 500 500
24. Board INSTRUMENT

Louver KEYMAN 2 200 400

25.
Compact BAJAJ 1 150 150
26. Fluorescent Lamp

Cost/Kg of CRCA 1 193 33357.6

28. Sheet

Additional Cost: 9000

Total Cost: Rs. 213247.6
 CONCLUSION
In the conclusion I would like to say that while doing this project I got the idea of
how "Tea Process Automation Project" works i.e., the basic control philosophy.
Also, to do a project what are the necessary steps that need to be followed from
the beginning to the end and how to prepare the documents; I learned while
working on the project. And finally got some good ideas about process control &
automation, and to do so how to sense the steps which are being followed
sequentially one by one, how to select appropriate components for a particular
project and cost analysis, preparing the appropriate 'Logic' and 'Fault Logic'
according to the requirement of the following project. Also learned about panel
designing and busbar calculations so all over gained a good knowledge regarding
a general process automation and its real time application in the industry.