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  • Annual PLC Section Expense Presentation

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    diego fuentes
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    The annual presentation document summarizes expenses for various plant sections (RC1-RC6) of a cement plant. RC1 accounted for the largest expense of Rs. 17,406,200. Breakdowns from May 2014 to March 2015 are also summarized, listing the section affected, reason for breakdown, duration and frequency. Proposed automation improvements are outlined, including upgrading servers, new Android and web applications, wireless systems, and various control upgrades.

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    The annual presentation document summarizes expenses for various plant sections (RC1-RC6) of a cement plant. RC1 accounted for the largest expense of Rs. 17,406,200. Breakdowns from May 2014 to March 2015 are also summarized, listing the section affected, reason for breakdown, duration and frequency. Proposed automation improvements are outlined, including upgrading servers, new Android and web applications, wireless systems, and various control upgrades.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
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    9 views18 pages

    Annual PLC Section Expense Presentation

    Uploaded by

    diego fuentes
    The annual presentation document summarizes expenses for various plant sections (RC1-RC6) of a cement plant. RC1 accounted for the largest expense of Rs. 17,406,200. Breakdowns from May 2014 to March 2015 are also summarized, listing the section affected, reason for breakdown, duration and frequency. Proposed automation improvements are outlined, including upgrading servers, new Android and web applications, wireless systems, and various control upgrades.

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    of 18

    Annual Presentation for

    PLC Section
    Unit wise expense
    RC2 756595, [PERCENTAGE]
    RC3 402815, [PERCENTAGE]

    RC4 430244, [PERCENTAGE]

    RC5 638637

    RC1 1740620, [PERCENTAGE]

    RC6 155020

    RC6
    100

    RM plc upgradation
    90 866812

    80

    Ramco tuning;
    RC1 Expense
    70 678640 Rs17,40,620
    60

    50

    40

    30

    20

    10 Shell scanner, wifiCables Other expense


    modem 78428
    41222 51567
    UPS card repair 23951
    0
    35Rockwell License
    Upgradation;
    318298

    RC2 Expense
    30

    25
    Rs 756586
    UPS card repair 204000
    20

    15

    RM plc upgradation
    108917
    10

    Shell scanner, wifi modem


    54859
    5 Cables 42078
    Other expense
    28246

    0
    25
    Box Panel;
    225000

    20 RC3 Expense
    Rs 4,02,815
    15

    10

    PLC Card; 61000

    5
    CCR Lab; 37000 Cable
    33000 Video kit 31000
    Other (Jyotsna Ent)
    15655

    0
    25
    Box Panel;
    225000
    MATERIAL EXPENSE

    20 RC4 Expense
    Rs 4,30,244
    15

    MATERIAL EXPENSE

    10 PLC Card; 91500


    OBCS
    70180

    5 U6 Sec Crusher; 44000

    0
    25

    Controlnet cable;
    20 195500
    PLC Card; 180236
    RC5 Expense
    Rs 6,38,635
    15
    Others; 135700

    10
    N/W H/W
    75700

    UPS Shifting;
    5 42200 Antivirus
    35600

    0
    7

    PLC Spare;

    RC6 Expense
    6 59000

    5 Rs 1,55,020
    KVM
    42000
    4
    Beltsway;
    33650

    Biometric Lock;
    20550
    2

    0
    Breakdowns & Problems(May-14)
    SECTION REASON DURATION FREQ. TOTAL

    CM3 DROP FAILURE PROBLEM 0.50Hrs 1 0.50Hrs


    Breakdowns & Problems(Jun-14)

    SECTION Stoppage Reason DURATION FREQ. TOTAL(Hrs)

    CM3 PLC DATA COMMUNICATION FAILURE 0.75Hrs 1 0.75

    CM3 R.P. PLC (ROLCOX PANEL) HANGED 1Hrs 1.00 1

    CM4 CNBR Hang Due to over heat 1Hrs 1.00 1.00


    Breakdowns & Problems(July-14)

    SECTION REASON DURATION FREQ. TOTAL

    WATER PUMP TRIPPED DUE TO PACKING PLANT UPS SUPPLY


    CM3 FAILURE 1.08Hrs 1 1.08Hrs
    Breakdowns & Problems(Aug-14)

    SECTION REASON DURATION FREQ. TOTAL

    CM3 ROLLER PRESS ROLCOX PANEL UNHEALTHY 4Hrs 1 4Hrs


    Breakdowns & Problems(Feb-15)

    SECTION REASON DURATION FREQ. TOTAL

    CM3 Controlnet cable damage due to excavation work 4.67Hrs 1 4Hrs


    Breakdowns & Problems(Mar-15)
    SECTION DATE REASON DURATION FREQ. TOTAL

    MARCH

    COMPRESSOR TRIPPED DUE TO


    CM3 08-Mar-15 0.42 1 1.08
    I/O SUPPLY FAILURE

    29-Mar-15 PLC RIOR REPLACEMENT WORK 1.58 1.00

    COOLER FAN 10 & 11 AND GRATE 1&2


    29-Mar-15 TRIPPED DUE TO L&T PLC DROP 0.17 1.00
    FAILURE
    KILN3 2.00

    30-Mar-15 KILN MAIN DRIVE COOLING BLOWER 0.25 1.00


    TRIPPED DUE TO L&T PLC FAILURE
    • INSTALLATION OF BLADE SERVERS TO
    UPGRADE OLD SERVERS FOR FAST
    SCANNING & TRENDING AND BETTER
    STORAGE OF DATA

    • GPP DATA TRANSFER BETWEEN CEMENT PLANT


    AND POWER PLANT OVER OPC TO AVOID ANY
    MISMATCHING IN PARAMETERS

    • NEW ANDROID APPLICATION FOR PLANT INDICATION TO GET


    INSTANT ACCESS TO MONITOR THE PLANT RUNNING STATUS
    ONLINE
    • INSTALLATION OF ALL IN ONE PC FOR
    CCR OPERATION FOR VIEWING

    • PREPARED LOGIC IN ALL THE UNITS TO CONTROL


    FLUSHING FROM KILN FEED FLOWMETER TO AVOID
    PLANT STOPPAGES DUE TO AIR SLIDE JAMMING

    • NEW WEB SERVER FOR PLC SECTION REPORTING


    • WIRELESS SYSTEM FOR PACKING PLANT
    FOR ONLINE CORRECTION AND
    REPORTING PURPOSE

    • XRF AND RAMCO COMMUNICATION OVER


    ETHERNET FOR FASTER AND TROUBLE FREE
    OPERATION OF XRF MACHINES AND RAMCO
    SYSTEM

    • AUTOMATION OF NEW PHYSICAL LAB


    • XRF MACHINE WIRELESS
    COMMUNICATION

    • INSTALLATION OF SEPARATE ANTI VIRUS SYSTEM


    FOR PLC NETWORK TO AVOID DATA LOSS DUE TO
    VIRUS ATTACKS

    • U4 CNA INSTALLATION FOR RAW MIX CONTROL IN STOCK PILES

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