Talon Garikayi c056634k - Final Automated Lubrication System Project For Simbi Plant With Cover Page Page

CHINHOYI UNIVERSITY OF TECHNOLOGY
FACULTY OF ENGINEERING
DEPARTMENT OF MECHATRONICS ENGINEERING
ATTACHMENT PROJECT
FOR
TALON GARIKAYI
REG NO: CO56634K

AT
S.I.M.B.I. PVT. LTD

(STEELMAKERS ZIM PVT LTD GROUP OF COMPANIES)
MASVINGO BRANCH
____________________________________________________________________ 1
Talon Garikayi B.Eng Honours Degree in Mechatronic Engineering, Chinhoyi
University of Technology- Automatic Lubrication System Project.
TITLE: AN AUTOMATED LUBRICATION SYSTEM PROJECT DONE AT
STEELMAKERS (PVT) LTD –SPONGE IRON PRODUCTION DIVISION (SIMBI
BRANCH) BY TALON GARIKAYI (C056634K).
THE PROJECT WRITE IS SUBMITTED IN PARTIAL FULFILMENT OF THE
REQUIREMENTS OF A BACHELOR OF ENGINEERING HONOURS DEGREE IN
MECHATRONIC ENGINEERING TO THE DEPARTMENT OF MECHATRONIC
ENGINEERING, CHINHOYI UNIVERSITY OF TECHNOLOGY UNIVERSITY
(2008).
__________________________________
PROJECT SUPERVISOR’S SIGNATURE
MR I. MUCHIMWE
GROUP INSTRUMENTS ENGINEER
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ACKNOWLEDGEMENTS
I want to sincerely thank Mr. Mpofu, Mr. Ncube and Mr. Towera the Instruments
Technicians for their support during my project research. I also want to thank the
Electrical Manager Mr. Siriheri for his unrufflable diligence and ability to understand my
questions during research although there seems to be some communication problems. Mr.
Munyariwa was always there for my questions during my period of internship at the
Electrical department. To a greater extent I want to thank Mr. Chigova the Mechanical
Supervisor for his rendered support during my time at the Mechanical Department.
Lastly I would like to thank Mr. I Muchimwe (Instruments Engineer), Mr. Jemias
Chakonda and Mr. C. Madiro (Student Engineers from NUST) for their support during
the whole research and my time as a trainee at SIMBI. Their ability to spend valuable
time during discussions can be partly attributed for the lengthy of this project.
This report would not have been complete without the support of my family and Mrs.
Linda Makura.
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CONTENTS PAGE
Contents Pages
Acknowledgements i
Abstract ii
Chapter One: Introduction 1
Chapter Two: Literature Review 2

2.0 Introduction to literature review 2
2.1Tribology 3
2.2 Fundamentals of Tribology 4
2.3 Grease as a Lubricant 5
2.5 Lubrication 8
2.4Valves 9
Chapter Three: Conceptual Designs and analysis from Chapters 4 to 915

3.0 Introduction 15
3.1The Design Matrix table 15
Chapter Four: Analysis of Chosen Solution

4.1 The Intelligence 17
4.2 SCADA system of the Project 20
4.3 Automation system of the Project. 21

4.4 Human Machine Interfacing
24
Chapter Five: Analysis of Chosen Solution

5.0 The VersaMax Controller 25
5.1 Introduction 25
5.2 Controller Details
26
5.3 Schematic representation of the PLC 27
5.4 The Control 29
Chapter Six: Analysis of Chosen Solution
6.0 The Main PLC Components 33

6.1 The CPU Details
33 6.2 The Hardware Configurations
33
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Chapter Seven: Analysis of Chosen Solution 52
7.1 Pneumatic Grease Pump 52
7.2 The Pressure Regulator 53
7.3 Pressure Calculations 53
7.4 Justification of Chosen Solution 54
Chapter Eight: Analysis of Chosen Solution
8.0 The Pressure Transmitter 56

8.1 The Honeywell ST300 Pressure Transmitter
56
8.2 Installation of ST300 58
8.3 Valve Orientation 59
8.4 Pipe Installation 60
8.5 Justification of Chosen Solution
61
8.6 The Air Compressor 62
8.7 The Lubricant Tank 63
Chapter Nine: Analysis of Chosen Solution
9.0 The Control System and Philosophy of the project 35
9.1 Manual mode 36

9.2 Auto Mode 36
9.3 De-Int. mode 36
Chapter Ten: Programming the Controller
10.0 PLC Programming 37

10.1 Ladder Logic Programming Software 38
10.2 Schematic representation of the control system components 42
Chapter Eleven: The Actuator
11.1 Introduction to Valves 43

11.2 Butterfly Valve as possible solution 43
11.3 Solenoid Valve as a Chosen solution 46

11.4 Justification of Chosen Solution 50
Chapter Twelve: Project Calculations 64

Chapter Thirteen: Schematic wiring representation of the project 69
Chapter Fourteen: Interfacing with SCADA CIMPLICITY Software 71
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Chapter Fifteen: Maintainability 75
Chapter Sixteen: Recommendations 76
Chapter Seventeen: References 77
Chapter Eighteen: Conclusion 78
ABSTRACT
STEELMAKERS ZIMBABWE (PVT) LTD is a privately owned company whose main

business is the mining and beneficiation of iron ore into sponge iron and this is done at its
Sponge Iron Division- Masvingo branch. The company has two main branches here in
Zimbabwe; one in Kwekwe and Masvingo. The Kwekwe branch manufactures steel using
the sponge iron from the Masvingo branch. The company also has several other branches
in Kenya, DRC and India. The Masvingo branch mines iron ore from Glenlivet and
processes it into sponge iron and has the capability of producing 100 tones of sponge iron
per day.
During sponge iron production, a Rotary Kiln and a Rotary Cooler Discharge are some
of the main machinery. The kiln is approximately 42m in length and has lubrication is
done on its sleeves. Lubrication is done manually using a hand pump, on 21/02/2008 in
the early stages of our 5th campaign production was stopped and the Kiln was put on hold
mainly because the main drive shaft was broken. After investigations were carried out,
poor lubrication method and human negligence during lubrication was considered to be
one of the major causes.
The main goal of this project is to design an automatic lubrication system that will be
able to control the lubrication system of the Rotary Kiln sleeves and Rotary Cooler
sleeves and able to be operated from either Auto or Manual means. This will increase
productivity, decrease human intervention, and increase product quality as well as the
health and safety of the workers.
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CHAPTER 1
INTRODUCTION
The overall objective of this project is to control the lubrication system of the Rotary Kiln
sleeves and Rotary Cooler Discharge. My research focuses on automatic lubrication
methods in order to increase productivity and minimize human intervention hence
improving product quality and human safety.
SIMBI is one of the major producers in sponge iron industry in Southern Africa. For its
product to satisfy international market and become globally competitive so that it can
easily outclass already established Asian and European producers there is need for it to be
technologically advanced. The current situation in the country of foreign currency
shortages can only be improved if exporting companies like SIMBI become
competitive.[2]
Product quality depends on many factors chief among them being the total time taken
from adding the raw materials to the discharge of product at the Cooler Discharge outlet,
since the kiln and the cooler rotates there is great amount of frictional force experienced
at the sleeves thereby increasing the production time. [3]
Design brief
To design an automated lubrication system for the Rotary Kiln and Rotary Cooler
Discharge sleeves.
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Justification of Problem
The problem of concern in this study is the effect of too high frictional forces on the
rotary Kiln sleeves and at the Rotary Cooler Discharge thereby increasing the load of the
drive causing the main shaft to experience and the efficiency of the rotary kiln, which is
the major unit of production in the plant.
So this study seeks to find ways of optimizing operating parameters: in particular drive
speed and production time in a way to keep the degree of metallization high while
protecting the rotary kiln from premature destruction. In particular this project seeks to
determine the optimum levels and lubricant supply that can maintain both metallization
and campaign period of the kiln high. Metallization of iron ore is the sole purpose of the
process protecting the metalliser of great importance.
Objectives
 To investigate the effect of lubrication on Rotary Kiln and Rotary Cooler.

 To determine the optimum lubricant supply that can affect the highest extent
of Kiln and Cooler rotation and maintain frictional force at lower levels.
 To continuously monitor the lubrication system and regulate the volume of
lubricant supply as per process demand.
Limitations.
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The design was confined to the automation of lubrication system so as to minimize the
use of manual lubrication currently being used. The results obtained from the research
were accounted by operating conditions and the available instruments at the plant.
CHAPTER 2
Literature review
2.0 Introduction
“A project is a set of files used to execute a control programme.” [4]

These file are the ones that I will try to research much into, they include:
 Operating System
 Software Package for that support the Control system
 Controller parameters and the SCADA packages
“Literature review is a process that involves finding, reading, understanding and forming
conclusions about the published research and theory on a particular topic”. [5]
The research thus used textbooks, discussions, presentations and the Internet to get
information about the subject relating to the objectives.
A number of subheadings derived from literature and other sources were gathered under
the guidance of relevance. This section focuses mainly on the main individual
instruments that are expected to be implemented on the automatic lubrication system. A
summary is given on each instrument yet they were dealt in depth on later chapters.
2.1 Tribology
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Tribology is the science and technology of interacting surfaces in relative motion. It
includes the study and application of the principles of friction, lubrication and wear. The
word "tribology" derives from the Greek τριβο ("tribo") meaning 'to rub', and ("logos")
meaning 'principle or logic'[6]
 Applications
The study of tribology is commonly applied in bearing design but extends into
other almost all aspects of modern technology, even to such unlikely areas. Any
product where one material slides or rubs over another is affected by complex
tribological interactions, whether lubricated (e.g. the rotary kiln sleeves and rotary
cooler sleeves) or unlubricated (for example, Kiln outlet hood area where high
temperature sliding wear in which conventional lubricants can no longer be used
and the formation of compacted oxide layer glaze. that have been observed to
protect against wear).
The frictional resistance was the same for two different objects of the same weight
but making contacts over different widths and lengths. Also observed that the force
needed to overcome friction is doubled when the weight is doubled. [7]
2.2 Fundamentals of Tribology
The tribological interactions of a solid surface's exposed face with interfacing materials
and environment may result in loss of material from the surface. The process leading to
loss of material is known as "wear". Major types of wear include abrasion (friction),
erosion, and corrosion.
Estimated direct and consequential annual loss to industries in Zimbabwe due to wear is
approximately 1-2% of GDP. Wear can be minimized by modifying the surface properties
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of solids by one or more of surface engineering processes (also called lubricant surface
finishing for frictional or adhesive wear). [8]
Engineered surfaces extend the working life of both original and recycled and resurfaced
equipments, thus saving large sums of money and leading to conservation of material,
energy and the environment. However none of the methods of reducing friction were
used mainly because of the diameter of the kiln.
2.3 Grease (lubricant)
Although the word grease originally described the rendered fat of animals, the term is
now applied more broadly to mean a lubricant of higher initial viscosity than oil,
consisting originally of a calcium, sodium or lithium soap jelly emulsified with mineral
oil.
2.3.1 Properties
A true grease consists of an oil and/or other fluid lubricant that is mixed with another
thickener substance, a soap, to form a solid. Greases are a type of shear-thinning or
pseudo-plastic fluid, which means that the viscosity of the fluid is reduced under shear.
After sufficient force to shear the grease has been applied, the viscosity drops and
approaches that of the base lubricant, such as the mineral oil. This sudden drop in shear
force means that grease is considered a plastic fluid, and the reduction of shear force with
time makes it thyrotrophic. It is often applied using a grease gun, which applies the
grease to the part being lubricated under pressure, forcing the solid grease into the spaces
in the part. [9]
Soaps are the most common emulsifying agent used, and the type of soap depends on the
conditions in which the grease is to be used. Different soaps provide differing levels of
temperature resistance (relating to both viscosity and volatility), water resistance, and
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chemical reactivity. Powdered solids may also be used, such as clay, which was used to
emulsify early greases and is still used in some inexpensive, low performance greases.
2.3.2 Uses
Greases are employed where heavy pressure exist, where oil drip from the bearings is
undesirable, and/or where the motions of the contacting surfaces are discontinuous so that
it is difficult to maintain a separating lubricant film in the bearing. Grease-lubricated
bearings have greater frictional characteristics at the beginning of operation. Under shear,
the viscosity drops to give the effect of an oil-lubricated bearing of approximately the
same viscosity as the base oil used in the grease. Lithium-based greases are the most
commonly used; sodium and lithium based greases have higher melting point (dropping
point) than calcium-based greases but are not resistant to the action of water. Lithium
based-based grease has a dropping point at 190 °C to 220 °C (350 °F to 400 °F).
However the maximum usable temperature for Lithium-based grease is 120 °C.
Grease used for axles are composed of a compound of fatty oils to which tar, graphite, or
mica is added to increase the durability of the grease and give it a better surface. [10]
2.3.3Additives
Teflon is added to some grease to improve their lubricating properties. Gear greases
consist of rosin oil, thickened with lime and mixed with mineral oil, with some
percentage of water. Special-purpose greases contain glycerol and sorbitan esters.. They
are used, for example, in low-temperature conditions. Some grease are labeled "EP",
which indicates "extreme pressure".
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Under high pressure or shock loading, normal grease can be compressed to the extent that
the greased parts come into physical contact, causing friction and wear. EP grease
contains solid lubricants, usually graphite and/or molybdenum disulfide, to provide
protection under heavy loadings. The solid lubricants bond to the surface of the metal,
and prevent metal-to-metal contact and the resulting friction and wear when the lubricant
film gets too thin. [11]
2.3.4 Other greases
Other types of lubricating material that are soft solids or high viscosity liquids at room
temperature are often called grease, though they may not exhibit the shear-thinning
properties typical of the oil/soap grease.
2.3.5Viscosity of hydraulic grease
The internal resistance to flow of a liquid is measured by a fluid’s viscosity. More

precisely absolute viscosity is defined in terms of the force between two parallel layers of
fluid for a certain slip velocity between them. This is represented by Newton’s equation
Very often a hydraulic fluid will be selected on the basis of its viscosity and the operating
temperature of the system.
A fluid will flow more easily the less viscous it is, since less energy is required to
overcome the internal frictional forces. Any saving in energy must be balanced against an
increase in leakage due to the lower fluid viscosity.
There are two measures of viscosity: absolute (also known as dynamic) and kinematics.
The S.I. unit for absolute viscosity is N s m-2 or Pa. The non-S.I. unit is the poise (P)
equivalent to 0.1 N s m-2 (not to be confused with the poiseuille (Pl), used in France, and
equal to 10 poise) though the centipoises (cP) are more commonly used. In the hydraulics
industry kinematic viscosity is more frequently used, where:
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The S.I. unit for kinematic viscosity is mm2s-1 which corresponds to the older but still
commonly used unit the centistoke (cSt).
Past measures of viscosity using arbitrary scales like Redwood No 1 seconds, Saybolt
Universal Seconds (SUS), or degrees Engler should no longer be used. These units have
been superseded by the empirical measures previously mentioned; conversion tables do
exist but are only true at a fixed temperature. [12]
 Effect of temperature on viscosity
The temperature and viscosity of hydraulic oil are inversely related; as temperature
increases, viscosity decreases. In order to define the kinematic viscosity of oil, its
viscosity is quoted at a set temperature (40ƒC for the ISO standard) and the oil is given a
value according to the viscosity index (V.I.). For example oil quoted as conforming to
ISO 22 will have a viscosity of 22 mm2s-1/ cSt at 40ƒC. [13]
 Effect of pressure on viscosity
Contrary to popular belief, varying pressure can lead to significant variations in viscosity.
In a closed flow circuit at a fixed temperature, a change in pressure of 40 MPa (400 bar)
can lead to a change of up to 8% in viscosity. However there are problems associated in
calculating this variation. [14]
 Density and specific volume
The density of mineral oils is typically around 870 kg m-3 (in comparison synthetic oils
usually have a density of around 1200 kg m-3). The specific gravity, the ratio of the
density of the fluid to the density of water, is a dimensionless quantity typically 0.87 for
mineral oils. [15]
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2.4Lubrication
Lubrication is the process, or technique employed to reduce wear of one or both surfaces
in close proximity, and moving relative to each another, by interposing a substance called
lubricant between the surfaces to carry or to help carry the load (pressure generated)
between the opposing surfaces. The interposed lubricant film can be a solid, (eg graphite,
MoS2) a solid/liquid dispersion, a liquid, a liquid-liquid dispersion (greases) or
exceptionally a gas.
In the most common case the applied load is carried by pressure generated within the
fluid due to the frictional viscous resistance to motion of the lubricating fluid between the
surfaces.Lubrication can also describe the phenomenon when such reduction of wear
occurs without human intervention (aquaplaning on a road).
The science of friction, lubrication and wear is called tribology.
When we talk about (adequate) lubrication smooth continuous equipment operation is

assumed, with only mild wear, and without excessive stresses within the lubricated
conjunctions to cause seizure at the conjunction, or break of any part of the equipment,
and when such a catastrophic event does occur it means that the lubrication has broken
down. [16]
2.4.1The regimes of lubrication
When progressively increasing the load between the contacting surfaces three distinct
situations can be observed with respect to the mode of lubrication, which are called
regimes of lubrication:
• Fluid film lubrication is the lubrication regime in which through viscous forces
the load is fully supported by the lubricant within the space or gap between the
parts in motion relative to one another (the lubricated conjunction) and solid-solid
contact is avoided.
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o Hydrostatic lubrication is a special case of fluid film lubrication in
which an external pressure is applied to keep the lubricant in the
conjunction, enabling it to support the external load.
o Hydrodynamic lubrication is also a special case of fluid film lubrication
which occurs when the lubricant is able to support the load without
external pressure, through hydrodynamic forces alone, which deform the
shape of the interposing lubricant film into a wedge shape and drags the
lubricant into the film, so that the externally applied load can be
supported.
• Elastohydrodynamic lubrication: The opposing surfaces are separated but there

occurs some interaction between the raised solid features called asperities, and
there is an elastic deformation on the contacting surface enlarging the load
bearing area whereby the viscous resistance of the lubricant becomes capable of
supporting the load. [17]
• Boundary lubrication (also called boundary film lubrication): The bodies come
into closer contact at their asperities; the heat developed by the local pressures
causes a condition which is called stick-slip and some asperities break off. At the
elevated temperature and pressure conditions chemically reactive constituents of
the lubricant react with the contact surface forming a highly resistant tenacious
layer, or film on the moving solid surfaces (boundary film) which is capable of
supporting the load and major wear or breakdown is avoided.
Boundary lubrication is also defined as that regime in which the load is carried
by the surface asperities rather than by the lubricant.
Besides supporting the load the lubricant may have to perform other functions as well, for
instance it may have to cool the contact areas, or to removes wear products, and for
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carrying out these functions the lubricant is constantly replaced from the contact areas
either by the relative movement (hydrodynamics) or by externally induced forces.
Lubrication is required for correct operation of mechanical systems engines, pumps,

cams, bearings, turbines, cutting tools etc where without lubrication the pressure between
the surfaces in close proximity would generate enough heat for rapid surface damage
which in a coarsened condition literally weld the surfaces together, causing seizures. [18]
2.5Valves
A valve is a device that regulates the flow of substances (gases, fluidized solids, slurries,
or liquids) by opening, closing, or partially obstructing various passageways. Valves are
technically pipe fittings. Valves are used in a variety of applications including industrial,
military, commercial, residential, and transportation. At SIMBI we have different types of
valves for different fluids but the most common valve is the gate valve. Some of the
valves are driven by pressure only; they are mainly used for safety purposes in bag filters.
I am going to use a valve for opening and closing the air supply to the pneumatic grease
pump.
2.5.1Application
Large varieties of valves are available and have many applications with sizes ranging
from small to large. The cost of valves ranges from very cheap simple disposable valves,
in some items to very expensive valves for specialized applications. Valves are almost as
ubiquitous as electrical switches. Often a valve is part of some object, the valve body and
the object made in one piece. Fluid systems in chemical and power plants and other
facilities have numerous valves to control fluid flow.
2.6.2Valve parts
 Body
The majority of the valve consists of the valve body, including most of the exterior. The
valve body is the vessel or casing that holds the fluid going through inside the valve.
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Valve bodies are most commonly made of various metals or plastics, although valve
bodies fused with glass laboratory items in one piece are also made of glass.
 Ports
The body consists of two or more openings, called ports from which movement occurs
from one opening to the next. These ports are controlled by the valve to control the fluid
flow. Valves with two or three ports are the most common, while valves consisting of four
or more ports are not as frequently used. Extra ports that are not needed can be closed off
by the valve. Manufacturing of valves often occurs with the intent that they will be
connected with another specific object. These objects can vary, but generally these
include some type of piping, tubing, or pump head. In some cases, a valve port is
immediately connected to a spray nozzle or container. To make a connection, valves are
commonly measured by the outer diameter the ports they connect to. For example, a 1-
inch valve is sized to connect to 1-inch outer diameter tubing.
Combined with a valve, ports have the ability to act as faucets, taps, or spigots, all while
one or more of its remaining ports are left unconnected. Most valves are built with some
means of connection at the ports. This includes threads, compression fittings, glue or
cement application (especially for plastic), flanges, or welding (for metals).
 Discs and rotors
Inside the valve body, flow through the valve may be partly or fully blocked by an object
called a disc. Although valve discs of some kinds of valves are traditionally disc-shaped,
discs can come in various shapes. Although the valve body remains stationary within the
fluid system, the disc in the valve is movable so it can control flow. A round type of disc
with fluid pathway(s) inside which can be rotated to direct flow between certain ports can
be called a rotor. Ball valves are valves which use spherical rotors, except for the interior
fluid passageways. Plug valves use cylindrically-shaped or conically-tapered rotors called
plugs. Other round shapes for rotors are possible too in rotor valves, as long as the rotor
can be turned inside the valve body. However not all round or spherical discs are rotors;
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for example, a ball check valve uses the ball to block reverse flow, but is not a rotor
because operating the valve does not involve rotation of the ball.
 Seat
The valve seat is the interior surface in the body which contacts or could contact the disc
to form a seal which should be leak-tight, particularly when the valve is shut (closed). If
the disc moves linearly as the valve is controlled, the disc comes into contact with the
seat when the valve is shut. When the valve has a rotor, the seat is always in contact with
the rotor, but the surface area of contact on the rotor changes as the rotor is turned. If the
disc swings on a hinge, as in a swing check valve, it contacts the seat to shut the valve
and stop flow. In all the above cases, the seat remains stationary while the disc or rotor
moves. The body and the seat could both come in one piece of solid material, or the seat
could be a separate piece attached or fixed to the inside of the valve body, depending on
the valve design.
 Stem
The stem is a rod or similar piece spanning the inside and the outside of the valve,
transmitting motion to control the internal disc or rotor from outside the valve. Inside the
valve, the rod is joined to or contacts the disc/rotor. Outside the valve the stem is attached
to a handle or another controlling device. Between inside and outside, the stem typically
goes through a valve bonnet if there is one. In some cases, the stem and the disc can be
combined in one piece, or the stem and the handle are combined in one piece.
The motion transmitted by the stem can be a linear push or pull motion, a rotating
motion, or some combination of these. A valve with a rotor would be controlled by
turning the stem. The valve and stem can be threaded such that the stem can be screwed
into or out of the valve by turning it in one direction or the other, thus moving the disc
back or forth inside the body. Packing is often used between the stem and the bonnet to
seal fluid inside the valve in spite of turning of the stem. Some valves have no external
control and do not need a stem; for example, most check valves. Check valves are valves
which allow flow in one direction, but block flow in the opposite direction. Some refer to
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them as one-way valves.
Valves whose disc is between the seat and the stem and where the stem moves in a
direction into the valve to shut it are normally-seated (also called 'front seated'). Valves
whose seat is between the disc and the stem and where the stem moves in a direction out
of the valve to shut it are reverse-seated (also called 'back seated'). These terms do not
apply to valves with no stem or to valves using rotors.
 Bonnet
A bonnet basically acts as a cover on the valve body. It is commonly semi-permanently

screwed into the valve body. During manufacture of the valve, the internal parts were put
into the body and then the bonnet was attached to hold everything together inside. To
access internal parts of a valve, a user would take off the bonnet, usually for maintenance.
Many valves do not have bonnets; for example, plug valves usually do not have bonnets.
 Spring
Many valves have a spring for spring-loading, to normally shift the disc into some
position by default but allow control to reposition the disc. Relief valves commonly use a
spring to keep the valve shut, but allow excessive pressure to force the valve open against
the spring-loading,
 Valve balls
A valve ball is also used for severe duty, high pressure, high tolerance applications. They
are typically made of stainless steel, titanium, Stellite, Hastelloy, brass, and nickel. They
can also be made of different types of plastic, such as ABS, PVC, PP or PVDF.
 Valve operating positions
Valve positions are operating conditions determined by the position the disc or rotor in
the valve. Some valves are made to be operated in a gradual change between two or more
positions. [19]
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CHAPTER 3
Conceptual Designs
3.1 Introduction
This chapter only focuses on the conceptual designs that can be implemented on
this automatic lubrication system. However I had restricted my conceptual
designs to at least 3 so as to reduce the size of the write up at the same time
clearly explaining my chosen possible solutions. I had included drawings of
which I used mainly 2 software packages, AUTOCAD2004 and CADKEY2004,
which were readily available at the company and nearby resource centers (local
library).
3.2 The Design Matrix Table
The use of a design matrix table enables the designer to have several choices and not to
be locked in one area as he tries to solve the problem at hand, this is the concept that I
learn from the late Mr. T Zhuga during our Engineering Design and Innovation Course.
This table clearly shows the minimum number of solutions that I can implement to solve
the problem at hand, however the information in bold constitute the chosen solution.
Having in mind the fact that I had to use available resources my design strategies mainly
focused on how to implement them by correctly interfacing the available instruments and
softwares.
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CONCEPTUAL DESIGNS AS AN OVERVIEW
CONTROLER  Programmable logic controller*
 PID
 Intel 8085 microprocessor
VALVE ACTUATOR  Butterfly valve
 Solenoid valve*
PUMP TYPE  Electrical pump
 Pneumatic pump*
 Manual hand pump
PRESSURE REGULATOR  One directional pressure regulator*
INTELLIGENCE  Model based adaptive control system
 Model free adaptive control system*
 Fuzzy logic controllers
SCADA TYPE  Wonderware
 Cimplicity*
 Genesis
LADDER PROGRAMME TYPE  Versapro*
LUBRICANT  Universal grease*
 EP2
PRESSURE TRANSMITTER  Honeywell ST300
A market research was carried out so as to come up with the conceptual designs above,
however all the conceptual designs were detailed in this Chapter so that one will
understand the main reason why I chose a particular instrument or software.
The information in Chapter 4 will also be helpful during installation and commissioning
of this Project as detailed information is provided and specifications clearly analysed
from all perspectives of Engineering.
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CHAPTER 4
ANALYSIS OF CHOSEN SOLUTIONS
4.1The Intelligence
Model-free adaptive (MFA) control system
My control system has a single input and a single output (SISO) so I decided to choose
MFA because it requires no model and has SISO characteristics.
 Features
o No precise quantitative knowledge of the process available.
o No process identification mechanism or identifier is included in the
system
o No controller design is require but to use the available PLC.
o No complicated turning of controller parameter is required.
o Stability analysis criteria are available to guarantee the open loop
system stability.
Overview
It consists of a single loop control system that includes a SISO process, a SISO MFA
controller (PLC) and a feedback loop.
Control objective
The control objective of the controller is to produce an output u(t) to force the process
variable y(t) to track the given trajectory of its set point r(t) under variations of set point
disturbances and process dynamics.
____________________________________________________________________ 23
The function of MFA controller is to minimize the error e(t) in an online function. The
minimization of e (t) is achieved by:
 The regulatory control capability of the MFA controller.
 The adjustment of the MFA controller weighing factors that allow the controller to
deal with the process dynamic changes, disturbances, and other uncertainties.
No model error em(t) needs to be minimized and only the error e(t) between set point r(t)
or PV and process variable y(t) needs to be minimized. [20]
SISO means Single input, Single Output
____________________________________________________________________ 24
d(t)
r(t) e(t) MODEL u(t) SISO x(t) y(t)

BASED PROCESS
y(t) CONTROLLER
MODEL
y(t) -
IDENTIFIER
e(t)
NAME: TALON G. PROJECT 24/04/008

COMPANY: SIMBI TITLE: MFA CONTROL SYSTEM
____________________________________________________________________ 25
SCADA as applied to lubrication system
SCADA –Supervisory Control and Data Acquisition the terms refer to large scale
distributed measurement and control system. The bulk of the site control is actually
performed automatically by a Remote Terminal Unit or PLC as for SIMBI most of the
control functions are restricted to basic plant override or supervisory level capability. It
includes all HMI controllers, I/O devices; networks and software (Cimplicity as for
SIMBI). It implements a distributed database, which contains data elements called points.
Hard point representative of actual O&I connected to the system. Soft point result of
mathematical \operations applied to hard and soft points. [21]
The diagram below shows how the SCADA Software interface is like. The main reasons
why I chose this SCADA package are that:
• It uses pictures which look almost like the actual instrument or machine in the
field and it is readily available at the company as compared to the other packages.
____________________________________________________________________ 26
Automation being carried out by Engineers, Mr. I. Muchimwe and Mr. Talon
Garikayi
4.2Automation as applied to lubrication system

Is the automatic processes done by machines with minimum to no human interference.
The Fig above clearly shows how I will be able to control the whole Lubrication System
from the Main control room. They will be two PCs, one for the Engineer on my Left and
the Station manager PC that carries the SCADA software.
As the name indicates, it is not a full control system, but rather focuses on the supervisory
level. As such it is a purely software package that is positioned on top of hardware to
which it is interfaced, via PLCs. The system collects data from various sensors in the
plant and then sends this data to a central computer that then manages and controls the
data. The plant control logic resides in the PLC and it does all the logic decisions. [22]
____________________________________________________________________ 27
Roles
• Aid humans
• Increase production
• Control management
• Increase precision.
Characteristics
• System must be safe
• System must be comprehensive
• System must have minimum human interference.
• Improve production, easy maintenance and cost effective.
Supervisory Control Architecture
INTERFACE
SUPERVISORY
DISPLAY CONTROL
SYSTEM
COMPUTER
HUMAN
INTERVENTION
CONTROL
SENSOR
____________________________________________________________________ 28
Control engineering is the engineering discipline that focuses on the modeling of a
diverse range of dynamic systems (e.g. mechanical systems) and the design of controllers
that will cause these systems to behave in the desired manner. Although such controllers
need not be electrical many are and hence control engineering is often viewed as a
subfield of electrical engineering.
Electrical circuits, digital signal processors and microcontrollers can all be used to
implement Control systems. Control engineering has a wide range of applications from
the flight and propulsion systems of commercial airliners to the production of sponge iron
at SIMBI.
Control engineers often utilize feedback when designing control systems. For example, in
temperature is continuously monitored and fed back to the system which adjusts the
motor's speed accordingly. Where there is regular feedback, control theory can be used to
determine how the system responds to such feedback. In practically all such systems
stability is important and control theory can help ensure stability is achieved.
Although feedback is an important aspect of control engineering, control engineers may

also work on the control of systems without feedback. This is known as open loop. A
classic example of open loop control is the opening and closing of my solenoid valve
given a signal from the.
Other functions of SCADA are:
• To generate trends and reports of the plant parameters.
• To generate alarms.
• To have graphical views of the whole plant.
• To provide troubleshooting guides.
So many SCADA packages are currently in use throughout the world. Some of the most
common ones are:
- Wonder ware
____________________________________________________________________ 29
- Cites
- Genesis
- RS View
- Cimplicity
At SIMBI, we use CIMPLICITY SCADA. It is important to note that SCADA is not a
controller but simply interfacing software between the controller and the operator’s panel,
the computer. [23]
4.4 The Human Machine Interface (HMI)

A SCADA system includes a user interface usually controls where the individual can
interface with the SCADA system. The SCADA system communicates with PLCs
throughout the system network and processes information that is easily disseminated by
HMI
At SIMBI we use two computers the Engineering PC and the Station manager PC for our
SCADA system. The only way one can communicate well with my design is through the
computer using the SCADA, this actually made my design user friendly and increased its
value as a fully automated project design hence easy to implement. [24]
The Human Machine Interface Characteristics
____________________________________________________________________ 30
CHAPTER 5
The Controller
5.0 The PLC (VersaMax Model)
____________________________________________________________________ 31
Inside the PLC panel (the selected project controller)
5.1 Introduction
I was trained on how to do fault finding and appreciate the need for a controller in the
processing industry so I compiled the information in this chapter with great caution since
any wrong information could lead to a disastrous future in the control engineering field.
Most of the literature was researched after practicals with the Instruments engineer. This
was one of the most challenging topics of my attachment since it strongly requires good
background of control engineering. Emphasis was on understanding the principle factors
under industrial measurement and control.
5.2 The Details of the Controller
____________________________________________________________________ 32
The GE Fanuc* PLC system consist of Ethernet based control processing unit and total
programming for monitoring and controlling the various equipment pertaining to the
plant.
A PLC is a microcomputer based controller that uses stored instructions in programmable
memory to implement logic, sequencing, timing, counting and arithmetic functions
through digital or analogue I/O module for controlling machines and processes. The
microprocessor is used for automatic distribution of real world process but designed for
an extended temperature ranges dirty or dusty conditions. It is immune to electrical noise,
mechanically more rugged and resistant to vibrations.
 Processor
It is the CPU of the programmable controller. It executes the various logic and
sequencing functions by operating on the PLC inputs to determine the appropriate output
signals. It consists of one or more microprocessors designed to facilitate I/O
transmissions. The GE Fanuc* PLC like all PLCs, it has inbuilt facilities like timers
counters, PID loops and parameters like memory bits registers, global bits, temporary
bits, and system bits that can be configured as per plant requirements through
programming software for the better monitoring and control of the plant.
 Memory unit
It is connected to the CPU; it contains the programs of logic sequencing and I/O
operations. It also holds data files associated with these programs including I/O status
bits, counter and timer constants, other variables and parameter values. This memory unit
is referred to as the user or application memory because it s contents are entered by the
user. In addition the processor has a system that directs the execution of the control
program and coordinates I/O operations. The contents of the system memory are entered
by the manufacturer and cannot be accessed or altered by the user.
____________________________________________________________________ 33
 Power supply
A power supply of typically 120VAC is used to drive the PLC some 230VAC .It converts
AC to DC of 5V. It often includes a battery back up that switches on automatically in he
event of an external power source failure. At SIMBI a UPS is connected in series and
there is a 230AC transformer of equal voltage on Primary and Secondary winding
responsible for smoothening the 230ACV. A number of breakers are installed in the PLC
panel for different inputs. These are:
• Transformer
• PC
• Digital output signals
• Digital input signals
• Analogue signals
NB: swichedmode power supply units are the ones in use.
 Input/ Output Module

Provides the connectors to the backplane and process that is to be controlled. Inputs to the
controllers are signals from he sensors and other ON/OFF devices. Outputs from the
controller are ON/OFF signals to operate actuators and other devices required to activate.
Many PLCs are capable of accepting continuous signals from analogue sensors and
operate signals suitable for actuators.
 Programming device
The PLC is programmed by means of a special programming device. It is detachable
from he PLC cabinet so that it can be shared among the controllers. A PC (as for SIMBI)
can be used, but usually remain connected to serve a process monitoring or supervision
functions related to the process.
 Expansion transmitter modules
____________________________________________________________________ 34
These modules are responsible for communication between the processor and the
input/output modules. There is a main ETM and is the one responsible for direct
communication and the rest of the ERMs behave as parasites.
General Structure of a PLC consists of the

• CPU,
• Output and Input modules,
• Power supply
• Detachable programming device
• Expansion transmitter modules
____________________________________________________________________ 35
5.3 Schematic representation o f the PLC
Mains supply
Digital Input and

Power Supply Output Modules
Detachable Processor
Programming device CPU
Analogy Input and

Output Modules
Memory unit
5.4 The Control Signals

 Digital Inputs
These are real discrete inputs from the field that will include limit switches for the stutus
of my solenoid valve , level switches for the level of my lubricant , flow switches, push
buttons for the condition of the pneumatic pump ,contactors, overload relays.
Digital input modules are configured to accept these inputs, which are connected to the
same power supply from the CPU.
____________________________________________________________________ 36
The switching mode for digital inputs can either be source mode or sink mode and are
activated on by either a 24 VDC, 110 VAC at 220VAC. The most common are the source
mode, which has a switching signal at the (+) positive. For sink mode, the switching
mode is (-) negative; therefore, the PLC will sink (switching a mental OV). At SIMBI
there are 32 input modules with a 24 VDC switching voltage (source mode).
24VDC
1
2
3
4
5
INPUT
MODULE
32
 Digital Output
Give out a voltage usually 24 VDC to field devices such as relays, contractors, transistors
depending on the type of PLC. Usually the output is a low current which is used to switch
a higher current or
 Analog Inputs
Receives signals from real world analog signals which will include the ST300 pressure
transmitters. Most common type of inputs are: 0 – 20mA; 0,-5V; 0,-10V; 1 – 5V, 1 – 10V
and 4 – 20mA. At SIMBI, the most widely used analog input is the 4 – 20 mA.
 Schematic representation of Analog Inputs
____________________________________________________________________ 37
Input module/card
Source voltage +
-CH1
24VDC
+
- CH2
+
TRANSMITER - CH3
+
- CHn
SENSOR
NB: The wiring of digital inputs is different from that of analogue inputs. If the 4 – 20
mA is coming from a transmitter, a power supply, in our case, of 24VDC is required.
 Analog Output Signals
Gives output commands to field devices such as control valves, pneumatic pump and
solenoid valve. The signal current operates the current to pneumatic converter.
+ Address: - % AQ 0001
CH1 -
+ To actuator
CH2 -
+
CH3- To actuator
____________________________________________________________________ 38
CHAPTER 6
The Main PLC Components
6.1 The CPU (Details)
Introduction
The Output and Input modules are fitted on the female connectors to enable
communication with the CPU, which is also placed on the back plane. The power supply
of the back plane is to supply some modules with power.
NB: Not all output and input modules get their supply from the power supply in the PLC,
but some input/output modules are supplied from the back plane.
Structure of a Module
Each back plane accommodates a specific number of modules and if the required
modules in a plant exceed the maximum number accommodated by a back plane, there is
need for an Expansion Transmitter Module which will enable the CPU on a certain back
plane to communicate with Input and Output Module in another back plane.
NB: All other modules which are connected on a different back plane from the one with
the CPU need an Expansion Receiver Module (ERM) which receives instructions or
signals from the Expansion Module (ETM).
All Analog Output Modules are powered from the back plane with a 5V supply. Digital
Output sends output to the relays, which will enable switching on of high currents. There
____________________________________________________________________ 39
are two types of relays in use, NO (normally open) and NC (normally closed) Each relay
has one digital output from the PLC.
Back Plane
This is the plane where digital/analog modules are mounted. At SIMBI, the back plane
can support up to 9 modules. Some of the output modules take their supply voltage from
the back plane, however at SIMBI most of the output modules are not supplied from the
back plane.
Expansion Transmitter Module (MDL 650)
It is the main transmitter from the CPU to the output modules. All other ERMs depend on
the ETMs thus; they behave in a parasite manner. For every backplane, we have the
ERM. In addition, when changing modules one should take note of the codes.
Digital outputs and inputs can be slotted on the same back plane but it is wise for
uniformity to separate them that is using different back planes.
At SIMBI, there are 7 digital output modules which translate to 7 x 32 output signals
from the PLC. In addition, there are also 17 digital input modules, which translate to 17 x
32 input signals.
NB: Analog Output Modules uses 24VDC from SMPS and Input Modules use 5VDC
from the back plane.
6.2 Hardware Configuration

When assembling a PLC you carry out hardware configuration first ie.
 Choosing the correct type of CPU
 Choosing the correct digital input card (32 port)
____________________________________________________________________ 40
 Selecting the type of mode (SIMBI uses source mode)
 Correctly, use slot number and rack number for the PLC to correctly identify the
Input/Output signals.
Relays
SIMBI uses 24VDC relays and they are high current rating relays. These are of two types,
Normally Open (NO) and Normally Closed (NC). Each digital output uses one relay .
LED
The LED ON, on the Modules only signal whether the signal from the instrument is
reaching the PLC. These LEDs are helpful during trouble shooting of an instrument.
Digital outputs have only 2 LEDs for power supply.
Terminal Block Side (TBS)
The blocks are used to connect the cables from the field to the PLC. This reduces the
number of cables into the PLC panel and provides SMART installation. Terminal blocks
on the terminal side also help a lot during troubleshooting. The cables are given addresses
for easy identification e.g.
Analog Outputs AQ0001 (Blue Cable)
Analog Inputs AI 0001
Digital Outputs R0001 (Blue cable)
Digital Q000I(Yellow cable)
NB: Take note that after expansion of the plant, some of the cables are not labeled and
the terminal side has changed a lot and is not yet updated.
____________________________________________________________________ 41
CHAPTER 7
The Pneumatic Pump and the Pressure Regulator
7.1 High Pressure (Grease Pump) Selection Guide
Each application varies and should be carefully considered for special conditions that
may require a pump selection other than the standard recommendations listed. These
conditions include, but are not limited to:
• Viscosity of product pumped

• Ambient temperature conditions
• Simultaneous operation of several dispensing outlets
• Dispensing volume requirements ,also when measuring total pump distance, the
hose length of dispensing reels should be included in total distance.
Pneumatic T-junction
A T-junction is a very small piece that allows three pieces of tubing to connect into one
junction, essentially splitting (or joining) airflow from two hoses into one. These only
allow 1:2 branching, but by combining T-junctions, any number of branches can be
achieved (i.e.: one tube can branch into three by using two T-junctions).
Pneumatic Tubing
Tubing is simply the means by which air power is transferred through the circuit. Tubing
can connect to a switch, air tank, T-junction, cylinder, pump, distribution block, or flex-
hose.Flex-hoses aren't actually considered pneumatic pieces; they were designed as part
of the Technic system for a different purpose, but I have discovered that pneumatic tubing
actually fits over flex hoses pretty well; so many people use them as tubing extenders
whenever they are needed. Flex hoses are more rigid than tubing. Most pneumatic tubing
____________________________________________________________________ 42
almost always comes with sets in an uncut form, and are required to be cut into smaller
pieces using scissors.
7.2 The Pressure Regulator
The first pressure regulator has to allow a constant air pressure supply of 140Kpa (21psi)
to be used as an input to the Current-to-Pneumatic converter.
The second pressure regulator has to allow a constant air pressure supply of 140Kpa
(21psi) to be used as an input to the Valve Positioner.
The pressure regulator is a normally open valve and is installed at the START of a system
or before pressure sensitive equipment to regulate or reduce undesirable higher upstream
pressure. Too often, a pressure regulator is installed. In this case, the pressure regulator
will simply stay wide open and just send liquid straight into the tank without maintaining
upstream pressure...just a very expensive fitting.
Where an obstruction will benefit everything after the valve, a pressure regulator should
be used so that not all the equipment after it will have excessive pressure. Used where it
should be that is at the beginning of a process, the pressure regulator will ensure safe
downstream pressure. The combination of a pressure regulator at the beginning of a
system, and a backpressure regulator at the end of a system, will ensure balanced pressure
throughout the system. This is a simplification, of course, and the specifics within any
given system can vary greatly.
7.3 Calculations.
Using the equation of continuity
A1 v1 = A2 v 2
Assumption: The flow rate at any point of the system obeys this equation
____________________________________________________________________ 43
By varying the area of the opening at the outlet of the regulator we can regulate the outlet
pressure.
Applying Bernoulli Principle, under steady state flow, well developed flow conditions the
total energy of a unit volume of material must be constant at every part of the system.
P1 v2 P v2
H1 + + 1 = H2 + 2 + 2
ρg 2 g ρg 2 g
P1 v2 v2
P2 =( H1 + + 1 −H 2 − 2 ) ρg
ρg 2g 2g
By increasing A2 we decrease v 2 and increase the pressure P2 thereby regulating

pressure.
7.4 Justification of chosen solution

Improved Control
• You can rely on this real-time information to make sound process management
decisions. By analyzing pressure dynamics through SCADA Software, you can
identify control areas needing improvement and maintain a high level of system
performance.
Environmental Protection
• You can avoid additional field wiring by connecting a leak detector or limit switch
to the auxiliary terminals of the solenoid valve, in this way, the instrument will
issue an alert if limits are exceeded.
____________________________________________________________________ 44
Enhanced Safety
• You can check the pressure regulator and keep the process running smoothly and
safely from a remote location. Access is possible during maintainence since one
can easily isolate the regulator using the isolating valves installed.
Hardware Savings
• Pressure regulator, when used in an integrated system, allow you to realize

significant hardware and installation cost savings by replacing other devices in the
process loop, such as suppressors and gauges.
Easy Maintenance
• Solenoid valves are modular in design. The module base can be removed from the
instrument housing without disconnecting the field wiring, pneumatic connections
or stem linkages. This module contains the critical sub-modules so component
removal is quick and simple.
____________________________________________________________________ 45
CHAPTER 8
8.0 The Pressure Transmitter
Introduction
This is an optional instrument that can only be used if there are enough resources at the
company. “We can not promise you that we need to monitor the pressure of the
pneumatic grease pump or the solenoid valve since we can find the types that can use line
pressure.”[9] Said Mr. I. Muchimwe (The instruments Engineer). However I do believe
this is a necessary instrument considering the fact that our plant is already highly
automated and we already have some pressure transmitters in stock.
8.1 Honeywell ST300 SMART Pressure Transmitter
Functional Principle
The transmitter is ready for operation immediately after installation. The settable
measuring span corresponds to the specification on the rating plate. If customized setting
____________________________________________________________________ 46
is made at the factor, the start of scale are specified o the measuring pate .If necessary, the
parameters can also be changed during commissioning by simple operating procedures.
Design
 The device consists of different components depending on what the
customer has specified in the order. The possible variants will be listed in
the operating manual.
 The rating plate with the order number is on the side of the housing. One
can determine the optional constructional details and the possible
measuring range (physical properties of the built –in sensor element) with
the specified number and specifications.
____________________________________________________________________ 47
Advantages
• A single technician can test the entire signal loop from a central location.
• Significant reduction in down time.
• Time savings during start up and maintenance
Disadvantages
• It is mainly suitable for absolute pressure measurements yet we want to measure

the differential pressure.
• I am not going to implement this type of pressure transmitter because it cannot
withstand the high temperatures experienced at the kiln section and I have to
implement a differential pressure transmitter.
8.2 Installation
We must not overlook the possibility of condensate freezing in impulse lines to

transmitters measuring gas pressure. Although these components could be heated similar
to water and steam applications, the simplest and best approach is to install transmitters
so that they are self draining. This means that the impulse lines are connected to the
lowest point in the transmitter meter body and the piping is sloped downward at least one
inch per foot. If the transmitter is located below the process taps, piping must still run
downward from the transmitter to the point and then to the process as shown below:
____________________________________________________________________ 48
When the transmitter is in its DE mode, the process variable is available for monitoring
and control purposes; and the meter body temperature is also available as a secondary
variable for monitoring purposes only.
8.3 Valve orientation
____________________________________________________________________ 49
____________________________________________________________________ 50
8.4 Pipe installation for Differential Pressure Transmitter
____________________________________________________________________ 51
8.5 Justification of Chosen Solution
Improved Control
performance.
Environmental Protection
• You can avoid additional field wiring by connecting a leak detector or limit switch
to the auxiliary terminals of the pressure transmitter, in this way, the instrument
will issue an alert if limits are exceeded.
Enhanced Safety
• You can check instrument and valve operation and keep the process running
smoothly and safely from a remote location. Access is possible at a field junction
box, marshalling panel, or within the safety of the control room using a system
workstation. Your exposure to hazardous environments is minimized and you can
avoid having to access hard-to-reach high temperature locations.
Hardware Savings
• Pressure Transmitter when used in an integrated system, allow you to realize
process loop, such as pressure gauges.
Easy Maintenance
• Pressure Transmitters are modular in design. The module base can be removed
from the instrument housing without disconnecting the field wiring, pneumatic
connections or stem linkages. This module contains the critical sub-modules so
component removal is quick and simple.
____________________________________________________________________ 52
8.6 The Air Compressor
At SIMBI, we use a Centrifugal air compressor -a vane rotating disk or impeller in a

shaped housing forces the gas to the rim of impeller increasing the velocity of the gas.
A diffuser (divergent duct) section converts the velocity energy to pressure energy. These
are used for continuous, heavy industrial uses and are usually stationary.
Their application can be from 100 hp (75 kW) to thousands of horsepower. With multiple
staging, they can achieve extremely high output pressures greater than 10,000 lbf/in² (69
MPa). Fluid-handling devices are not concerned with the modulation of power, but only
with the movement of fluid. Choosing a fluid-handling valve used to be easy, because
each one had its own area of utility.
For on off, full, or no-flow requirements, ball and gate valves were favored; where tight
shut-off was not required, butterfly and slide valves were used.
As a result, beliefs were formed which may inhibit the selection of the best valve for my
design.
8.7 The Lubricant Tank
This is the container where the pneumatic pump shall be mounted. This tank also serves
the purpose of storage of the lubricant during lubrication. A number of factors were
considered during the selection of the tank.
 Pump distance that is the distance to be traveled by the lubricant before it reaches
its intended point of lubrication.
 Number of outlets.
 Maximum pressure the pneumatic pump will be exerting.
 Tubing pipe size.
____________________________________________________________________ 53
The Lubricant tank diagram
____________________________________________________________________ 54
____________________________________________________________________ 55
CHAPTER 9
The Control System
9.0 Control Philosophy
As an abstract, the plant has been divided into four major segments.
i) Kiln and Cooler Section
ii) Waste Gas Section
iii) Product Separation Section
iv) Raw material handling section
The corresponding signal from every individual section has been connected to the PLC
system through the corresponding Input and Output modules. The CPU is continuously
processing the data as per the program logic and communicating the SCADA – Graphical
interface terminals for equipment status, monitoring and control.
The proposed PLC is user friendly and during the operation, in case of any fault due to
malfunction of any input address, the same can be reset by assigning some other address
from the spare block for ensuring the smooth functioning of the plant.
The necessary interlocks have been incorporated for every equipment to safe guard from
any eventualities and ensuring the smooth operation of the plant.
The system is designed to operate in 3 modes mainly:
i) Manual
ii) Auto
iii) DE INT
____________________________________________________________________ 56
9.1Manual Mode
In this mode, the system can be started / stopped through SCADA i.e. from computer.
Here we can start all drives as well as conveyers by clicking the respective icons. All
interlocks are applicable in this mode.
9.2 Auto Mode
Generally, the system is operated in this mode. Here the system is designed in such a way
that the entire plant can be started with one click or individual major sections can be
started one by one.
9.3 DE INT Mode
In this mode, all the drives can be started/stopped independently irrespective of the
interlocks and is generally used for maintenance purposes.
The selection of the control of the plant is achieved by selecting LOCAL/REMOTE

positions in the MCC. To operate the plant in Auto mode all the selector switches should
be in REMOTE mode. When the system is in Auto mode, if any of the selector switches
in a particular group changes to LOCAL mode, then the whole group trips along with
down stream groups.
NB; In case it is necessary to keep one or few drives out of the total sequence of
operation, this is achieved by putting them in DE INT mode.
____________________________________________________________________ 57
CHAPTER 10
Programming the Controller
10.0 PLC Programming
Introduction
A program is a set of instructions to execute a certain function. The instructions to be

performed during each scan are coded and inserted into memory with the programs.
Programming is carried out using a programming unit, which provides an interface
between the PLC and the user during program development, start up and trouble
shooting.
What makes a PLC special? PLC's are used to automate machinery in assembly lines.
For our (plant) project, we use the computer link feature that allows a PLC to take
commands and communicate with a host computer. If something goes wrong with the
computer link, the PLC still functions and protecting valuable equipment. This PLC and
most others use a language called relay ladder logic programming. Normally in a
programming language things happen in order.
The command or line of code on top is executed before the command on the bottom until
you hit the end of a loop. This is not so in ladder logic. Everything happens at the same
time.
So what is ladder logic programming really like? Ladder logic programming looks, well,
like a ladder. It's more like a flow chart than a program. There are two vertical lines
coming down the programming environment, one on the left and one on the right. Then,
you have rungs of conditionals on the left that lead to outputs on the right.
____________________________________________________________________ 58
The things you will probably use the most writing Ladder Logic are the relay conditionals
--| |-- ---|/|--- and the output coils --- ( ) ---. These three things basically make up a kind of
IF THEN statement.
10.1 Ladder logic Programming Software
Ladder logic Programming Software is a method of drawing electrical logic schematics.

It is now a graphical language very popular for programming PLCs. It was originally
invented to describe logic made from relays. The name is based on the observation that
programs in this language resemble ladders, with two vertical "rails" and a series of
horizontal "rungs" between them.
A program in ladder logic, also called a ladder diagram, is similar to a schematic for a
set of relay circuits. An argument that aided the initial adoption of ladder logic was that a
wide variety of engineers and technicians would be able to understand and use it without
much additional training, because of the resemblance to familiar hardware systems.
(This argument has become less relevant given that most ladder logic programmers have
a software background in more conventional programming language and in practice
implementations of ladder logic have characteristics — such as sequential execution and
support for control flow features — that make the analogy to hardware somewhat
imprecise.)
Ladder logic is widely used to program PLCs, where sequential control of a process or
manufacturing operation is required. Ladder logic is useful for simple but critical control
systems, or for reworking old hardwired relay circuits. As programmable logic controllers
became more sophisticated it has also been used in very complex automation systems.
____________________________________________________________________ 59
Manufacturers of programmable logic controllers generally also provide associated
ladder logic programming systems.
Typically, the ladder logic languages from two manufacturers will not be completely
compatible; ladder logic is better thought of as a set of closely related programming
languages rather than one language (the IE 61131-3 standard has helped to reduce
unnecessary differences, but translating programs between systems still requires
significant work).
Even different models of programmable controller within the same family may have
different ladder notation such that programs cannot be seamlessly interchanged between
models.
Ladder logic can be thought of as a rule-based language, rather than a procedural

language. A "rung" in the ladder represents a rule. When implemented with relays and
other electromechanical devices, the various rules "execute" simultaneously and
immediately.
When implemented in a programmable logic controller, the rules are typically executed
sequentially by software, in a loop. By executing the loop fast enough, typically many
times per second, the effect of simultaneous and immediate execution is obtained. In this
way it is similar to other rule-based languages, like spreadsheets or SQL. However,
proper use of programmable controllers requires understanding the limitations of the
execution order of rungs.
Hence a program is a set of instructions to execute a certain function. The instructions to

be performed during each scan are coded and inserted into memory with the programs.
Programming is carried out using a programming unit, which provides an interface
between the PLC and the user during program development, start up and trouble
shooting.
____________________________________________________________________ 60
The flowchart representing the execution of tasks by the controller (PLC)
START
SWITCH ON THE
POWER SUPPLY TO THE
SOLENOID VALVE
CHECK THE VOLUME

OF THE LUBRICANT IN
THE TANK
IS THE KILN
NO AND
COOLER
ROTATING
YES
NO
IS THE AIR
COMPRESSO
R
YES
ENERGIZ
E THE
SOLENOI
D VALVE
PNEUMATIC
PUMPING
OPERATIONAL
DE-
ENERGIZE
THE
SOLENOID
VALVE
FIN ISH
____________________________________________________________________ 61
START OF SWEEP
HOUSEKEEPING
HOUSEKEEPING
I/O
ENABLED
INPUT SCAN
DATA INPUT
RUN
MODE
LOGIC SOLUTION
PROGRAMME
EXECUTION
I/O
ENABL
ED
OUTPUT SCAN DATA OUTPUT
PROGRAMMER
COMMUNICATIONS
PROGRAMMER
SERVICE
SYSTEM
COMMUNICATIONS
SYSTEM
COMMUNICATION
APPLICATION PROGRAM
CHECK SUM CALCULATIONS,

VERIFICATION AND
PROGRAMME CONFIGURED
DIAGNOSIS
____________________________________________________________________ 62
fig
____________________________________________________________________ 63
The Control and Power wiring diagram for the Lubrication System
____________________________________________________________________ 64
fig
____________________________________________________________________ 65
Ladder Diagram for the Automated Lubrication System
10.2 Schematic representation of the Control System components
COMPRESSOR FILTER PRESSURE

REGULATOR
PLC SOLENOID
“CONTROLLER” VALVE
PNEUMATIC PUMP
LUBRICANT
SCADA ROTAY KILN AND

“STATION MANAGER”
Fig 13
____________________________________________________________________ 66
CHAPTER 11
11.0 The Actuator
11.1The Valve
Introduction
The valve will be used to allow the compressed air to switch on the Pneumatic pump; this
will be done on well calculated intervals.
11.2The butterfly valve-not a chosen solution
The Butterfly valve (actuator) will receive a pneumatic signal of 80 psi from the valve
positioner. I decided to use the type of butterfly valve described below because of its
ability to withstand vibrations and high temperatures experienced at the plant.
Triad offers direct mount rack and pinion pneumatic actuators that have double travel
stops insuring precise seating of disc. These actuators are available in both double acting
and spring return versions.
The actuator is corrosion resistant inside and out. Available accessories include modular
mount positioners, pilot solenoid valves and limit switch assemblies.
Were once used for low-pressure service where complete shutoff was not necessary, and
they were not used to modulate flow. Butterfly valves had the advantage of small size,
lightweight, simple design, and low-pressure drop. They also required only a one-quarter
turn to change from closed to the fully open position.
Today, butterfly valves retain their traditional virtues. But capabilities have been greatly
extended by offset discs and polymeric seals. These and other design innovations have
____________________________________________________________________ 67
enabled butterfly valves to be used for throttling, tight sealing, and withstanding
pressures as high as 1,200 psi while retaining many traditional advantages.
A modern butterfly valve may include a pressure-tight resilient seat and an angularly
offset disc. Other butterfly valve designs use a hard seat and an O-ring or piston ring
around the disk to seal. Butterfly valves range in size from small to enormous, and are
well suited for large flows of gases, liquids, or slurries.
The system offers long cycle life and a corrosion-free mating surface. The valve has a
ductile iron disc, resilient seat, and self-lubricating sleeve bearings, self-adjusting /wear
compensating shaft seal, and taper pins that lock the disc to the shaft to prevent leakage.
The plant uses mostly wholly mechanical butterfly valves, situated on a rugged
environment with great vibrations hence their principle of operation involves the use of
dents and a pointer. Statistics reveal that most workers do not correctly set the valves
giving wrong feedback information to the plant operator.
Some employees do not understand the importance and usually ignore to check the status
of the valves leading to poor production so I decided not to use a gate valve but managed
to choose a solenoid valve.
Reasons for rejection as a choice
This type of valve is wholly mechanical therefore it will be impossible to activate it from
the Central Control room so that the control system becomes automatic. I however intent
to use it as an in-line valve that can work if my regulator fails to operate during
production process.
____________________________________________________________________ 68
Fig 14 SAP-CAD drawing showing the gate valve
____________________________________________________________________ 69
11.3 The Solenoid valve- chosen valve for the control system
 Principle of operation
Solenoid valve is an electromechanical valve for use with liquid or gas controlled by
running an electric current through a solenoid, which is a coil of wire, thus changing the
state of the valve. The operation of a solenoid valve is similar to that of a light switch, but
typically controls the flow of air or water, whereas a light switch typically controls the
flow of electricity.
Solenoid valves may have two or more ports: in the case of a two-port valve the flow is
switched on or off; in the case of a three-port valve, the outflow is switched between the
two outlet ports. Multiple solenoid valves can be placed together on manifold. Solenoid
valves are the most frequently used control elements in fluidics.
Their tasks are to shut off, release, dose, distribute or mix fluids. They are found in many
application areas. Solenoids offer fast and safe switching, high reliability, long service
life, good medium compatibility of the materials used, low control power and compact
design.
Besides the plunger-type actuator, which is used most frequently, pivoted-armature

actuators and rocker actuators are also used.
 The structure
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.
Solenoid valves may use metal seals or rubber seals, and may also have electrical
interfaces to allow for easy control. A spring may be used to hold the valve opened or
closed while the valve is not activated.
____________________________________________________________________ 70
____________________________________________________________________ 71
____________________________________________________________________ 72
The cross-section showing the finer details of a solenoid valve and its
construction. From the diagram one can deduce that the opening and
closing of the valve has a great relationship with the energizing and
de-energizing of the coil.
This is a SAP-CAD drawing which uses mainly ACAD2004
THE SOLENOID VALVE
____________________________________________________________________ 73
11.4 Justification of my choice
For my design I am going to use a 2-way solenoid valve to totally open or totally close
thereby restricting the pneumatic signal required by the pneumatic grease pump during
lubrication. The solenoid valves are controlled by an electrical signal from the SCADA.
Improved Control
performance.
Enhanced Safety
• You can check instrument and valve operation and keep the process running
smoothly and safely from a remote location. Access is possible at a field junction
box, marshalling panel, or within the safety of the control room using a system
workstation. Your exposure to hazardous environments is minimized and you can
avoid having to access hard-to-reach high temperature locations.
Hardware Savings
• Solenoid valve, when used in an integrated system, allow you to realize
process loop, such as positioners and limit switches, with just opening or closing
of the valve by the movement of coil.
Easy Maintenance
• Solenoid valves are modular in design. The module base can be removed from the
instrument housing without disconnecting the field wiring, pneumatic connections
____________________________________________________________________ 74
or stem linkages. This module contains the critical sub-modules so component
removal is quick and simple.
CHAPTER 12
The Calculations
The Equation of Continuity as statement of mass conservation
The Law of Conversation of mass states that mass can be neither created nor destroyed.
Using the Mass Conversation Law on a steady flow process - flow where the flow rate
don't change over time - through a control volume where the stored mass in the control
volume don't change - implements that inflow equals outflow.
This statement is called the Equation of Continuity.
Common application where the Equation of Continuity can be used are pipes, tubes and
ducts with flowing fluids and gases, rivers, overall processes as power plants, diaries,
logistics in general, roads, computer networks and semiconductor technology and more.
The Equation of Continuity and can be expressed as:
m = ρi1 vi1 Ai1 + ρi2 vi2 Ai2 +..+ ρin vin Aim
= ρo1 vo1 Ao1 + ρo2 vo2 Ao2 +..+ ρom vom Aom (1)
where
m = mass flow rate (kg/s)
ρ = density (kg/m3)
v = speed (m/s)
____________________________________________________________________ 75
A = area (m2)
With uniform density equation (1) can be modified to
q = vi1 Ai1 + vi2 Ai2 +..+ vin Aim
= vo1 Ao1 + vo2 Ao2 +..+ vom Aom (2)
Where
q = flow rate (m3/s)
ρi1 = ρi2 = ρin = ρo1 = ρo2 = ρom
Pipe equations
 Calculating cross-sectional area, weight of empty pipes, weight of pipes filled

with grease, inside and outside surface area.
Pipe cross-sectional area, empty pipe weight, pipe filled with water weight, inside and
outside pipe surface area for a unit length pipe can be calculated with the equations
below.
Cross Sectional Area
Cross-sectional Area of a Steel Pipe can be calculated as
A = 0.785 di 2
where
A = cross-sectional area of pipe (Square Inches)
di = inside diameter (inches)
____________________________________________________________________ 76
Weight of Empty Steel Pipes
Weight of empty steel pipes can be calculated as
wp = 10.6802 t (do - t)
where
wp =weight of steel pipe (Pounds per Foot Pipe)
t = pipe wall thickness (Inches)
do = outside diameter (inches)
Weight of Water in Pipes filled with Water
Weight of water in pipes filled with water can be calculated as
ww = 0.3405 di 2
where
ww = weight of steel pipe filled with water (Pounds per Foot Pipe)
Outside Surface Area of Pipes
Outside surface area of steel pipes can be calculated as
Ao = 0.2618 do
where
Ao = outside area of pipe - per foot (Square Feet)
____________________________________________________________________ 77
Inside Surface Area of Pipes
Inside surface area of steel pipes can be calculated as
Ai = 0.2618 di
where
Ai = inside area of pipe - per foot (Square Feet)
Area of the Metal
Area of the metal can be calculated as
Am = 0.785 (do 2 - di 2)
where
Am = area of the metal (Square inches)
• Lubrication intervals calculations

After research using statistical data available and gathering information from the
Mechanical Supervisors at the plant I managed to deduce that lubrication of the Kiln
Sleeves is done after every 2 hours. I deduced the following calculations using my
design parameters.
Lubrication interval = 2hours
____________________________________________________________________ 78
Pump capacity = 1L/min
Sleeve requirements = 1L/2hrs
Total number of switching ON of pump per day:
24hrs
=
2hrs =12times / day
Total litres of lubricant pumped per day:
=12 x1l
= 12 Litres
Lubricant container volume = 210 Litres.
Total number of days the lubricant can be applied before refill:
210l
=
12l / day
Therefore the system can run up to a maximum of 388 hours before refilling the
container.
Fail Safe Mode of the Control System
Total number of liters: 210 Litres

Residual volume of lubricant after 388 hours:
=210litres −204litres
=6litres
Thus the total number of lubrication intervals that can be attained after an alarm for
refilling the tank has been flagged are:
6litres
=
1litre
=6
____________________________________________________________________ 79
The total number of hours the pneumatic pump can be operational before automatically
switching OFF even when the tank is not refilled are:
=6 ×2hours
=12hours
The timers in the circuit were used to attain the “fail safe mode” of the whole project.
Engineering thermodynamics as applied to the automatic lubrication system design

project.
Calculations
Consider a small interval of time dt and small mass of lubricant dmi entering the
system and dw small amount of work done by the pump given that the energy of the
system is Es.
Assumptions
To facilitate the application of Laws of Thermodynamics to this lubrication system lets
consider a closed system, knowing that the lubricant is filled in the tank at a different
activity with draining the lubricant for application.
At time = ( t +dt )
The differential change of State
• Assume all properties of the lubricant are uniform during filling the container and
of lubricant.
Then ∑dQ −∑dW =∆E
Thus the first Law of Closed system can be stated as follows,
∑dQ −∑dW = E S ( t +dt ) +E s ( t )
____________________________________________________________________ 80
Hence at time t the total energy ET of the system is given by,
1 2
= E s ( t ) +dmi (u f +
2 ci
E T (t )
+g z)i
And at time ( t +dt ) the equation becomes.

1 2
= E s ( t ) +dmo (u f +
E 2 ci z)
T (t )
+g i
The workdone in time dt is equal to the workdone by the pump shaft plus flow work.
dW f
+dW sh =dW T
Therefore the work transfer turn on the pump shaft is given by the shaft work and the
flow work
∫dW = P 2V 2
−P1V 1
The flow work can be expressed as follows,
∫dW f =P 2V 2
−P1V 1
Substituting relevant expressions we deduce the following,
1 2
= E s ( t ) +dmo (u f +
2 ci
E T (t )
+g z) i
From the equation on the previous page I can substitute for enthalpy then divide by
dt having in consideration that my system has one inlet and one outlet.
Final Assumptions
• Assume there is no boundary movement.
• Mass flow rate of the system is constant and the same at inlet and outlet.
• Properties of fluid at any point in the system remain constant with time.
• Heat and work across boundaries of the system are at a constant rate.
____________________________________________________________________ 81
CHAPTER 13
The Schematic Wiring Representation of the Project.
____________________________________________________________________ 82
13.1 The Parts list
NB: most of the parts on the list are the main parts hence some bolts and nuts are not
listed down so during installation please make use of the cost analysis table at the end of
this write up.
Part Name of Component Quantity

Number
9 Backflow valve 1
8 Distribution container 1
7 Strainer 1
6 Lubricant storage tank 1
5 Pneumatic grease pump 1
4 Control valve/pressure transmitter 1
3 Solenoid valve 1
2 Pressure regulator 1
1 Isolating valve 6
CHAPTER 14
Interfacing with SCADA- Cimpilicity Software
Drawing the Object using CIMPLICITY Software
____________________________________________________________________ 83
o Go to new Project then click Enter.
o Go to symbols and import the necessary symbols to form the object.
o Choose correct colours
NB: Knowledge of AUTOCAD or Microsoft picture editor is a requirement.
Creating object CIMPLICITY Software

 Select Object Properties.
 Declare the addresses that was used on the Ladder Logic Programme i.e. %M this
will enable the CIMPLICITY Software to identify the signal status from the
Ladder Programme.
Colour Animation
• Colours can be imported from the colour folder hence there is need to clearly
analyse the feasibility of your addresses especially internal memory signals.
START: %M001 Hold-in Contact

%M001 [0] Gray (with all downstream interlocks OK)
%M001 [1] Green (the pneumatic pump will be pumping)
STOP: %M002 Auxiliary Contact
%M002 [0] Gray (with all interlocks in good condition, no EMEGENCY switch ON)
%M002 [1] Red (the pneumatic pump will not be pumping and the system is OFF)
PUMP COLOUR: %M003
%M003 [0] Red (the Control system is OFF)
%M003 [1] Green (the Control system is ON)
CHAPTER 15
Maintainability
____________________________________________________________________ 84
My main concern was to ensure that my project would not become a liability for the
company because of unnecessary breakdowns and easy wear and tear of instruments, on
selecting each and every component in the system I did analysed the strength of material
used and whether it can survive in such a rugged condition.
I do not hesitate to note that my system design is easy to maintain since the solenoid
valves that I used are the same as those already in use at the plant, of which I can say they
are easy to maintain.
My system does not require special skills to implement it or to use it, therefore there is no
need to retrain the Control room operators or instruments Technicians on how best to run
the automated lubrication system.
On the other hand this system is “automatic” so there is minimum- to- no human
interference so its maintainability is easier than any control system at the plant as no
routine work is done on it.
During production the whole system can easily be maintained because the pneumatic
pump does not have down stream interlocks with other plant circuits as compared to
drives and other machinery at the plant. Thus one can easily change the solenoid valve or
pneumatic pump during plant RUN.
During shutdown the total time required to service the whole Lubrication system is
minimum as compared to other control systems at the plant.
CHAPTER 16
Recommendations
____________________________________________________________________ 85
While selecting the type of tubing to be implemented I had problems on locating the
rubber tube so I recommend that all the tubes be done using steel pipes which can
withstand high pressures.
Installation of instruments which uses pneumatic signals has always been a challenge to
most Technicians so I recommend that during installation of this system a pipe fitter be
present and also no leakages should be allowed as this can cause some energy loses as
well as wastage of precious compressed air.
The lubricant is ordered in 25litre containers which will in turn be opened and used to
refill the 210 Litre main Lubricant tank, I recommend that 210 Litre containers be bought
directly from the supplier, and then the pneumatic pump may simply be installed at the
containers.
Although it was easy to come up with solutions there had been difficulties in choosing
the best solution as the company authority restricted my solutions to those with the
resources which are already available so as to cut the project total cost, I however
recommend that there should be no restriction on possible solutions as long as they are
feasible hence the company have to be in a position to meet some extra cost.
CHAPTER 17
REFERENCES
[1] SIMBI information desk.

[2] www.zim.steelmakers.com/simbi
____________________________________________________________________ 86
[3] SIMBI information desk.
[4] Mr. I. Muchimwe (STEELMAKERS Group Instruments Engineer)
[5] Engineering Design and Innovation Lecture notes from the Mr. T Zhuga.
[6] Introduction to Tribology by D.Bargarao.
[7] Tribology Analysis by Professor da Vinci University of Twentwe. (U.T)
[9] www.industriallubricants.com/grease
[11] Introduction to Thermal Expansion Vol.2 by W. Gupta
[12] Tribology Analysis by Professor da Vinci University of Twentwe. (U.T)
[13] Fluid Power and Drives Lecture notes by Mr. D. Wakasemwa
[16] Introduction to Thermal Expansion Vol.2 by W. Gupta
[17] www.industriallubricants.com/lubrication
[18] Introduction to Tribology by D.Bargarao
[19] www.valves.com/solenoid
[20] Intelligent Machine and Interfacing Lecture Notes by Mr. T. Zhuga
[21] Industrial Automation Lecture Notes by Mr. T. Zhuga
[22] Intelligent Machine and Interfacing Lecture Notes by Mr. T. Zhuga
NB: all calculations were done using the combination of notes from my tutorials that
I had attended at C.U.T.
CHAPTER 18
____________________________________________________________________ 87
Conclusion
In conclusion the main objective of this project was to come up with the solution for
lubricating the kiln and cooler sleeves of which I believe I did. This project was more
difficult than the one I did at the University in my 2nd Year because I had to focus on
implementation of the system too rather than coming up with just a write up of the
project.
Installation and commissioning of this project is due on the next plant-shutdown of which
by then I would have submitted the write up to the Department of Mechatronics at CUT.
However with the vast exposure I had in Control Systems I do believe the Installation and
Commissioning of this project is going to be easy since I also have worked with the
Instruments Engineer- Mr. I Muchimwe, Mechanical Supervisor- Mr. B. Bvude and the
Process Engineers – Mr. Ravi Kumar and Mr. E Mugodi so as to come up with the write
up.
The project actually presented an opportunity to combine the knowledge that I had gained
from my Lectures at University and the practical work that I had carried out on my
attachment at the company. Also I had the opportunity to learn much on how to gather
relevant information from field experts.
At this point it was now clear to me that coming up with an industrial solution to a
problem requires team work.
This project was so difficult to come up with since researching using the internet was too
expensive and I was also too busy since I was now employed as an Instrumentation and
Control Technician.
To a greater extent this project was successful on solving the project at hand.
____________________________________________________________________ 88

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CHINHOYI UNIVERSITY OF TECHNOLOGY

DEPARTMENT OF MECHATRONICS ENGINEERING

REG NO: CO56634K

S.I.M.B.I. PVT. LTD

STEELMAKERS (PVT) LTD –SPONGE IRON PRODUCTION DIVISION (SIMBI

BRANCH) BY TALON GARIKAYI (C056634K).

THE PROJECT WRITE IS SUBMITTED IN PARTIAL FULFILMENT OF THE

REQUIREMENTS OF A BACHELOR OF ENGINEERING HONOURS DEGREE IN

MECHATRONIC ENGINEERING TO THE DEPARTMENT OF MECHATRONIC

ENGINEERING, CHINHOYI UNIVERSITY OF TECHNOLOGY UNIVERSITY

PROJECT SUPERVISOR’S SIGNATURE

GROUP INSTRUMENTS ENGINEER

Chapter Two: Literature Review 2

Chapter Three: Conceptual Designs and analysis from Chapters 4 to 915

3.1The Design Matrix table 15

Chapter Four: Analysis of Chosen Solution

4.3 Automation system of the Project. 21

Chapter Five: Analysis of Chosen Solution

Chapter Six: Analysis of Chosen Solution

6.0 The Main PLC Components 33

8.0 The Pressure Transmitter 56

Chapter Nine: Analysis of Chosen Solution

9.0 The Control System and Philosophy of the project 35

9.1 Manual mode 36

Chapter Ten: Programming the Controller

10.0 PLC Programming 37

Chapter Eleven: The Actuator

11.1 Introduction to Valves 43

11.3 Solenoid Valve as a Chosen solution 46

Chapter Twelve: Project Calculations 64

STEELMAKERS ZIMBABWE (PVT) LTD is a privately owned company whose main

 To investigate the effect of lubrication on Rotary Kiln and Rotary Cooler.

“A project is a set of files used to execute a control programme.” [4]

2.2 Fundamentals of Tribology

2.3 Grease (lubricant)

2.3.4 Other greases

2.3.5Viscosity of hydraulic grease

The internal resistance to flow of a liquid is measured by a fluid’s viscosity. More

 Effect of temperature on viscosity

 Effect of pressure on viscosity

 Density and specific volume

The science of friction, lubrication and wear is called tribology.

When we talk about (adequate) lubrication smooth continuous equipment operation is

2.4.1The regimes of lubrication

• Elastohydrodynamic lubrication: The opposing surfaces are separated but there

Lubrication is required for correct operation of mechanical systems engines, pumps,

 Discs and rotors

A bonnet basically acts as a cover on the valve body. It is commonly semi-permanently

 Valve operating positions

3.2 The Design Matrix Table

Model-free adaptive (MFA) control system

r(t) e(t) MODEL u(t) SISO x(t) y(t)

NAME: TALON G. PROJECT 24/04/008

4.2Automation as applied to lubrication system

Supervisory Control Architecture

Although feedback is an important aspect of control engineering, control engineers may

4.4 The Human Machine Interface (HMI)

The Human Machine Interface Characteristics

5.2 The Details of the Controller

 Input/ Output Module

 Expansion transmitter modules

General Structure of a PLC consists of the

Digital Input and