PLCSBC1.doc

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www.final-yearproject.com | www.finalyearthesis.com

SIR C.R.REDDY COLLEGE OF

ENGINEERING

PLC Based sequential batchprcess cntrl s!ste"

AUTHORS : Srinivas Nyayapathi,

Sri Ram Naresh Gorthi.

YEAR : III B.E.

DISI!"INE : E.I.E.

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ABSTRAT

Programmable logic controllers are extensively used in industries for

controlling sequence of actions of the process. The sequence of process flow is

decided for controlling the parameters like level and temperature. The brain of the

system is PLC .Appropriate hardware for interfacing the process to the controller is

developed for controlling the level ant temperature of the process. or controlling

sequence of actions ladder diagram is developed.

Programmable Logic Controller !PLC" is designed to operate in real time

environment. #t has been observed that in many industries distributed control system

and PLCs are extensively used. PLC based sequential batch process control

!PLC$%C" is a laboratory type setup. This setup will be useful for demonstrating the

use of PLC in sequential control operations in industry and development of ladder

diagram for particular application. The system under consideration is designed to

carry out sequence of events. The process under consideration is %atch process&

whish is controlled by PLC.




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DESIGN O# HARD$ARE O# THE

SYSTE%

The basic components of developed system are as follows

'" P()C*$$ TA+,

-" PLC

" T*/P*(AT0(* C)+T()LL*(

1" L*2*L C)+T()LL*(

3" #+L*T 2AL2* C)+T()LL*(

4" )0TL*T 2AL2* C)+T()LL*(

5" P0/P C)+T()LL*(

6" $T#((*( /)T)( C)+T()LL*(

7" P)8*( $0PPL9 $*CT#)+

PROCESS TANK:

or experimental setup there are two iron tanks '"process tank -" sump tank.$ump tank is used for circulation of water. #n the process tank& two level switches aremounted and the distance between the low level switch is ::mm .




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PLC:

PLC is sophisticated controller module used for controlling various operations of theprocess. PLC accept the input from the process and according to the ladder diagram#t gives output to the process as per the requirement. The ladder diagram isdeveloped according to the determined sequence of operations.

LEVEL CONTROLLER:

The process tank is required to be filled with water to a certain level. ;ence it isrequired to control level in the tank. Tank level control unit consists of the following

'" sensor

-" relay driver circuit

loat level sensors are used for sensing the level in the tank. Level floats that areused in the process are of magnetically coupled type. 8henever level of water goesup to the required level then high signal is given to the PLC by the float sensor. #nturn & PLC turns ) the inlet valve. ;ence relay


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PLC turns )+=) the motor depending on the sequence of the program developedfor PLC. 8hen stirrer motor is operated then corresponding L*> on the front panelof the control box will glow.

TEMPERATURE CONTROLLER:

#t is required to control the temperature of water in the process tank. #t consists offollowing units.

'" sensor-" signal conditioning circuit" relay driver circuit

(T> PT


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START/STOP SWITCH AND TEMPERATURE SET POINT ARRANGEMENT:

$tart=stop switches and set point knob are provided on the front panel of the controlbox. $tart switch starts the process and stop switch stops the process. Thetemperature set point is provided with the help of set point knob control box alsoconsists of L*> indicators to observe the online status of process.

Figure 1 HARDWARE DA!A" #F $HE %&%$E"

DESIGN OF SOFTWARE OF THE SYSTEM :

The PLC is programmed to provide system operation in a manner illustrated& insimple form in flow chart. The whole software is grouped into following parts.




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CONTROLLER PROGRAM FOR HEATER CONTROLLER:

Two heaters are provided for heating the water in the process tank. The rotary isswitch of the front panel provides temperature set point. 8hen the water temperaturein the process tank is less than that of set point of temperature provided then it wouldturn on both the heaters. ;eaters will be turned ) when the temperature in theprocess tank reaches upto the set point of temperature.

Figure )ADDER DA!RA"




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F)#W*HAR$

Figure / F)#W *HAR$




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PLCSBC1.doc