SUMMER TRAINING REPORT HINDALCO INDUSTRIES LIMITED

Summer Training Report

on Instrumentation in fabrication Plant At HindalcoSubmitted Industries By : UNDEFINED

3/21/12 INTEGRITY

COMMITTMENT

ECE 7th Sem SEAMLESSNESS

PASSION

SPEED

Table of Contents

Hindalco Industries Limited Overview Ø Fabrication / Instrument Department Ø Remelt Shop Ø Extrusion Press Ø Rolling Mill Ø Chemical / P. T. Lab Ø Product Range Ø PLC Basics Ø3/21/12 PLC Simple Programming Ø

INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Hindalco - An Overview

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

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Hindalco - Integrated Operations Raw Materials Raw Materials ( Bauxite ) Co- Generation

Caustic Soda

Power By Renusagar Power Plant

Aluminium fluoride

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Instrument Department Instrumentation Plant is R & D and maintenance Department of Hindalco. Ø 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. Ø

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Remelt Shop

The are various types of shop comes under the Remelt shop like Properzi, Cooling Tower R & D. 3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Extrusion Press

Extrusion Press is system that reduces the Diameter of various types of Billet( Solid Aluminium Rod). 3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Rolling Mill

Rolling mill is the System which reduces the thickness of the materials and produces thin sheets from slabs. 3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Chemical Lab

Chemical Laboratory Finds the various types of alloy combinations and the property of the aluminium after mixing the 3/21/12 INTEGRITY PASSION SEAMLESSNESS SPEED alloy. COMMITTMENT

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. 3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Hindalco Product Range

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

PLC Basics : Description This Presentation introduces the basic hardware and software components of a Programmable Controller (PLC). It details the architecture and basic instruction set common to all PLC’s. 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 PLC’s. 3/21/12 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.

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

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.

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

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.

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Leading Brands Of PLC AMERICAN 1. Allen Bradley 2. Gould Modicon 3. Texas Instruments 4. General Electric EUROPEAN 1. Siemens 2. Klockner & Mouller 3. Festo 4. Telemechanique JAPANESE 1. Toshiba 2. Omron 3. Fanuc 4. Mitsubishi 3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Areas of Application

¥

Manufacturing / Machining

¥

Food / Beverage

¥

Metals

¥

Power

¥

Mining

¥

Petrochemical / Chemical

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

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

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Tank Used to Mix Two Liquids

A

MOTO R FLOAT SWITCH

F S

SOLENOIDS

B

SOLENOID

C TIME R

1 -MINUTE

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Major Components of a Common PLC

POWER SUPPLY

From SENSORS Pushbuttons, contacts, limit switches, etc.

I M N O P D U U T L E

O M PROCESSOR

U T P U T

O D U L E

To OUTPUT Solenoids, contactors, alarms etc.

PROGRAMMING DEVICE

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

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

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

I/O Module DC INPUT MODULE IS NEEDED TO: • Prevent voltage transients from damaging the processor. •Helps reduce the effects of electrical noise

USE TO DROP THE VOLTAGE TO LOGIC LEVEL

FROM INPUT DEVICE

Current Limitin g Resisto r

OPTOISOLATO R

Buffer, Filter, hysteresis Circuits

TO PROCESSOR

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

I/O Module DC / AC OUTPUT MODULE IS NEEDED TO: • Prevent voltage transients from damaging the processor. •Helps reduce the effects of electrical noise

FROM PROCESSOR

TTL Circuits

OPTOISOLATO R

Amplifier RELAY TRIAC RESISTO R

TO OUTPUT DEVICE

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

INPUT / OUTPUT INPUTS

OUTPUTS

MOTOR CONTACTOR PUSHBUTTONS

PLC LAMP

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

PLC Connection L2

CONTACTOR

L1

N. O

L2 L1

C

FIELD WIRING

L1

3/21/12 INTEGRITY

OUTPUT MODULE WIRING

CONTACTO R COMMITTMENT

O: 4

MOTOR SOLENOID •VALVES •LAMP •BUZZER •

L2

0 PASSION

SEAMLESSNESS

SPEED

Discrete Input A 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 switch Normally Closed switch Normally Open contact Normally closed 3/21/12 contact INTEGRITY COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

IN

OFF Logic 0

PLC Input Module 24 V dc

IN

OFF Logic 1

PLC Input Module 24 V dc

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Analog Input An 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 Transmitter

IN

PLC Analog Input Module

Tan k

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Digital Output A 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

Lamp

Digital Output Module

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Analog Output An 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 transducer OUT

PLC

0 to 10V

Analog Output Module

E

Supply air

P

Pneumatic control valve

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Basic Function of PLC While 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 Scan PHASE 2

Program Execution PHASE 3

Diagnostics/ Comm PHASE 4

Output Scan 3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Selecting a PLC Criteria • • • • • •

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

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

PLC Programming Software Examples 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

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

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.

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Coil s 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.

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

AND OPERATION A Rung

C B

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).

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

OR OPERATION C

A Rung B

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).

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

NOT OPERATION C

A Rung

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.

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

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_con troller en.wikipedia.org/wiki/PLC program-plc.blogspot.com

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED

Thank You !

Thank You For Giving Your Valuable Time !

3/21/12 INTEGRITY

COMMITTMENT

PASSION

SEAMLESSNESS

SPEED