Acknowledgement

Main aim of this practical training is to get practical knowledge about the working of an industry and use of modern engineering in it. Training makes us to know how the knowledge from book is applied to practical life. During my schedule in H.Z.L., Debari, I got an opportunity to know about the working condition in plant and got more knowledge about my branch of study. ehind completion of this training, some persons played a key role directly or indirectly. !o I would like to thank those persons without whose contribution this work pro"es too much for me. I e#press my deep regards and gratitude to honorable Mr. Pankaj Joshi Head of $lectrical Department for suggesting the ad"ice, keen interest, and constant boost up, in"aluable guidance. I am grateful to Mr.B.P.Kant working at HZL, Debari. for gi"ing me guidance, kind support and mental preparation for training report. I am thankful and grateful to Mr.P.K.JAIN !r.Manager %H&D'( at H.Z.L., Debari %&)*.( for gi"ing me chance of training at their prestigious industry, which will be helpful in my progress toward bright future. I am also helpful to the e#ecuti"e staff, technical and non+technical staff of H.Z.L. for e#tending their kind support, information and practical knowledge during my four+week practical training at their unit H.Z.L., Debari, ,daipur.

Preface

-ractical training is a way to implement theoretical knowledge to practical use. To become a successful engineer it is necessary to ha"e a sound practical knowledge because it is the only way by which one can ac.uire proficiency / skill to work successfully in different industries. It is pro"en fact that bookish knowledge is not sufficient because things are not as ideal in practical field as they should be. Hindustan Zinc Ltd. is one of the best e#amples to understand the production process / producti"ity in particular of Zinc. It is a matter of great pleasure that our college authorities ha"e recommended a practical training of 01 days to supplement our theoretical knowledge ac.uired in the college. This report is an attempt made to study the o"erall production system / related action of Zinc !melter, Debari a unit a HZL. It is engaged in the production of high grade Zinc metal / other byproducts "i2. 'd, !ulphuric acid etc. since 3456 adopting hydro metallurgical technology.

Contents
1. ABOUT HIDUSTAN ZINC LTD. 1-25
3( Introduction777777777777777777777777777778 9( -roperties of Zinc %metallic( at 940:77777777777.................................6 0( )pplications of Zinc7777777777777777777777777...6 ;( !afety Department7777777777777777777777777......4 8( Zinc smelting steps in <arious plant7777777777777777777..31 8.3( &oaster plant777777777777777777.7777777....31 8.9( oiler ckt777777777777777777777777777..3; 8.0( )cid plant777777777777777777777777777.3; 8.;( Leaching / -urification plant7777777777777777777..35 8.8( &esidue Treatment plant777777777777777777777...34 8.5( Zinc dust plant7777777777777777777777777..34 8.=( Zinc $lectrolysis / Melting7777777777777777777791 8.6( !olution 'ooling / !torage77777777777777777777.91 5( 'entral >orkshop77777777777777777777777777..93 =( Instrumentation Department7777777777777777777777..9;

2. P OJ!CT "- STUD# O$ P O% AMMABL! LO%IC CONT OLL! S

3( Introduction 777777777777777777777777777.95 9( ?eed of -L' 77777777777777777777777777....9= 0( -lc past and present777777777777777777777777796 ;( )d"antages of -L'7777777777777777....................................01 8( -L' features777777777777777777777777777...03 5( Internal architecture of -L'777777777777777777777...09 =( The -L' system Hardware7777777777777777777777.;3 6( -rinciple of @peration 777777777777777777777777;0 4( -L's "ersus @ther Types of 'ontrols777777777777777777.;; 31( -rogramming of -L'77777777777777.. 77777777.......;8 33( -rogrammable Logic 'ontrollers %-L's( !pecifications7777777777781 39( )d"ancements in -L'777777777777777777777777.8; 30( Distributed 'ontrol !ystem %D'!(7777777777777777777..85 3;( Hybrid !ystems77777777777777777777777777786

&. CONCLUSION ' BIBLIO% APH# (((.................................5)-*+

ABOUT HINDUSTAN ZINC LTD.

1. In,ro-./,ion"
Hindustan Zinc Limited %HZL(A

@ne of the IndiaBs leading Zinc -roducers and e#ceptional in its e#tent of this technological complete with "ertical integration I? other non+ferrous metals. HZL was incorporation on 31th Cebruary 3456 as a public sector company after the take o"er of the $rstwhile Metal 'orporation of India. It was e#panded on December 34=5 and later on )pril 3468. The foundation stone of this company is being kept by !hri Manu hai !hah Minister of Industry on 95 *une 3459. HZL operations are broad lend based / its acti"ities range from e#ploration, mining / are processing to smelting and refining of -b, Zn, 'd, 'o, 'u / other precious metals. It also produces sulphuric acid and rock phosphate. Total plant area is 911.0 Hectare of HZL, Debari. Total Zinc production of Hindustan Zinc is =0915Tonnes per )nnum and maDor suppliers of HZL are Cinland, !weden and Eermany.

 O01r0i12"
Na31 ' Lo/a,ion " Debari Zinc !melter, <illage Debari , A41 ,daipur %&aDasthan( " Ceb.3456 %;1 years( $#panded Dec.,34=5 Pro/1ss Co01r1- Ar1a 5Ha6 To,a7 P7an, Ar1a 5Ha6 )pril 3468 / Dec.9111 " Hydrometallurgy " 99.58 " 395

Zinc !melter Debari is hydrometallurgical smelter producing high grade Zinc metal and other by products like 'd and !ulphuric )cid since 3456. 1. O81ra,in4 Ca8a/i,9" Zn )cid 'd Zinc dust 2. :ork ;or/1" <=* Nos. A A A A A A 6; ?os 86 ?os. =94 ?os. 38;?os. 888?os. 981?os. A A A A 61,111MT 301,111MT 981MT 051MT

Managerial / $ngineering !taff !uper"isory / Technical !taff Labour %a( !killed %b( !emi+!killed %c( ,nskilled

>. a2 Ma,1ria7 S.887i1s"%a( %c( Zawar Mines &aDpura Dariba Mines %b( )gucha Mines

&. Pro-./, B.91rs"%a( %b( %c( Tata hel !teel 'ompanies

5. S,18s o; 8ro/1ss"-

Mining

&oasting

Leaching

$lectrolysis Melting Zinc Ingots

5*6

Ma?i3.3 Po21r D13an-" - 06+;1M>

5=6 Pro/1ss Co77a@ora,ors"3. :rebs -enorro"a, CranceA+ Leaching, -urification, $lectrolysis 9. Lurgi, EM H, and EermanyA+ &oaster and gas clearing 0. )uto :umpu, CinlandA+ &T-, >artsila -lant

;. I.!.'., )LL@F, ,.:.A+ Zinc dust plant, )llen -ower -lant

2. Pro81r,i1s o; Zin/ 531,a77i/6 a, 2)>A

3. 9. 0. ;. 8. 5. =. 6. 4. 31. 33. 39. Density Melting -oint !pecific Latent Heat of Cusion !pecific heat capacity Linear e#pansi"ity Thermal conducti"ity $lectric !ensiti"ity Temp. 'oefficient of resistance Tensile !trength $longation FoungB modulus -assionBs &atio A A A A A A A A A A A A =3;1:g.Gm0 540: 31 *G :g 068 *G:gG: 03G: 333 >GmGk 8.4 ohm Hmeter ;1Gk 381 Mpa 81I 331 Epa 1.98

>. A887i/a,ions o; Zin/"

%a70aniBin4" It is one of the best forms of protection against corrosion, used e#tensi"ely in building, construction, infrastructure, household appliances, automobiles, steel furniture, etc. Zin/ O?i-1" Most widely used 2inc compound, 2inc o#ide is used in the "ulcani2ation of rubber, as well as in ceramics, paints, animal feed and pharmaceuticals, and many other products and processes. ) special grade of 2inc o#ide has long been used in photocopiers.

Zin/ Di1 Cas,in4s" Zinc is an ideal material for die casting and is e#tensi"ely used in hardware, electrical e.uipments, automoti"e and electronic components. o771- Zin/" Zinc sheet is used e#tensi"ely in the building industry for roofing, flashing and weathering applications. Zinc sheet is also used in graphic art to make plates and blocks, as well as battery callots and coinage. A77o9s" Zinc is e#tensi"ely used in making alloys such as brass, an alloy of copper / 2inc.

&. Sa;1,9 D18ar,31n,"

!afety is a degree of control o"er ha2ards. >orkers working in the factory are e#posed to all sorts of dangers so some personal protecti"e e.uipment are a"ailable to protect them head to toe such as+ 3. $ar Muff 9. Dust Mask 0. Cace !hield ;. Eas Mask 8. Elo"es 5. Eoggles =. Helmets 6. Leg Euard 4. &espirators 31. &ubber )pron 33. &ubber Eum oots 39. !afety all 30. !afety shoes

Cactori2ing the entire operation to safe se.uence efficiency in carefully performing the work. Cor the welfare of group in which the worker attached, you and your own protection of Dob. )ccidents are caused due to following reasons 3. ,nsafe 'ondition 9. ,nsafe )ct Unsa;1 Con-i,ion" !uch condition includes leaking gases / unprotects able machines, not furnace, professional ha2ard, occupational diseases pre"ailing in the industry. Unsa;1 a/," These accidents happen due to la2iness and negligence of the rules while he is on duty.

%1n1ra7 .71s an- Sa;1,9 3. e alert on work / do it in attention.

9. >orking place path should be clean. 0. )lways use safety belt while climbing up ladders. ;. Take help from skilled worker to start machine. 8. >aste dirt should not be scattered in ?arrow !treet. 5. !cattered thing stored in proper place. =. efore eating meal, wash hands / clean nail.

6. >hile working in hot place put on asbestos glo"es. 4. DonJt store guiding wheel at moisturi2ed place, donJt use them at higher than rated speed. 31. DonBt pass beyond the chain block or come when hea"y loading is being done.

5. Zin/ s317,in4 s,18s in Cario.s 87an,"

5.16 OAST! PLANT

This is the first department, where the treatment of 2inc is being done. Zinc sulphide is carried on con"eyer belts to the furnace. Here 2inc+sulphide is con"erted into 2inc o#ide or calcine. !@ 9 is a by product of the process which is further used for obtaining H 9!@; in the )cid -lant. !@9 is harmful so it is reco"ered by the .uenching tower, -E'T, >ET.

Pro/1-.r1Zinc concentrate handling system consists of two -hases i.e. phase 3 and PHAS! I- 'oncentrate comes from ZM and &)M. These concentrate are Transported by trucks and dumpers from mines and all unloaded on surface gri22ly of under ground hopes. !eries of belt con"eyors Transfer the concentrate from under ground hopper to blend storage yard. ,nloading on different heaps is done with the help of triple con"eyor. The storage yard is di"ided into parts for ZM, &DM and &)M. To a"oid wind losses water is sprayed through sprayer or manually by using Hose pipes. This also to maintain re.uired moisture in concentrates. The water spraying is done manually whene"er needed. PHAS! 2)cti"ities of phase 9 are as follows+ Zinc 'oncentrates of different mines from storage yard are charged in the underground hoppers %31;) and 31; ( in the re.uired ratio with the help of Tere#.. Mi#ing ratio is decided by a"ailability of concentrate from different units. The criterion of mi#ing is marinating Zinc and !ulphur 'ontent min. 81I and 96I respecti"ely. )lso feed back from reaching and electrolysis about cathode sheet .uantity is taken into consideration. Zinc dross %from Zinc melting section is also added along with concentrates in "ery little .uantity. The mi#ture of different concentrate %called blend( is transported to bins of &oaster+ 3 and II and with the help of series of belt con"eyors and a "ibrating screen which allows only under si2e material to go bins. phase 9.

@"ersi2e materials is ground in a hammer Mill and charged back to 31; ) and 31;

hoppers. )n

electro magnet is pro"ided on one of the 'on"eyors to attract and separate iron pieces, if any going to bins. >ater is also sprayed on 31= / 316 belt 'on"eyors to increase moisture is blend feed. Minimum 6I moisture is maintained in blend feed. !ample is drawn from e#traction belt and is analy2ed for moisture twice in a shift. )ll operation of starting the con"eyors is done by an operator deputed at control room of blend yard. Zinc blend is taken from the blend bin through e#traction belt to rotary table feeder and high speed feed machine. Then blend is fed to fluidi2ed bed roaster through furnace feed hole. Zinc blend is roaster to produce 'alcine and sulpher dio#ide gas. 9ZnsK0@9 9ZnoK 9!o9K heat )ir for roasting of Zinc blend supplied through roaster air blower continuously to roaster furnace through no22les. 'alcine form furnace comes out through o"er flow, under flow, boiler, cyclones and hot gas precipitator which is sent to reaching plant through screw con"eyors is air cooled and other con"eyors are water cooled for cooling of calcine. Hot gases with fine calcine particles coming from roaster furnace pass waste heat boiler in which hot gases are cooled, and steam is produced by circulation of DM water in boiler tube bundles. >ater is also circulated in furnace cooling coil installed in furnace hearth to maintain the desired bed temperature. Eases lea"ing waste heat boiler are passed through cyclone to remo"e the calcine particles and then passed through hot gas precipitator to remo"e the fine particles of calcine by the application of electric field. Eases lea"ing the hot gas precipitator are passed through scrubbing tower to cool down. In scrubbing tower spraying of water is done from top and gases entre from the bottom. Dust free gases from the scrubbing tower are passed through star cooled for further cooling. The gases lea"ing from star cooler are passed though electro filter to remo"e the miss completely. So-i.3 si7i/a,1 -osin4" - !odium silicate dosing is done in scrubber circulating water to remo"e fluoride from !o9 bearing gases as per following reaction H ?a9 !i@0 K 5HC ?a9 !iC5 K 0H9@

The dosing system consists of a sodium silicate storage tank, dilution tank, pump tank and dosing pump %9?os.(. Dilute solution of 8I strength is prepared in dilution tank and dosing sate is decided as per fluoride content in concentrate as per instruction of day Mgr %p(G Mgr %p(.

Ceed in $#traction elt &otary Table Ceed Machine )ir lower &oaster Curnace >ater heater boiler 'yclone HEID Can !odium !ilicate Eas !crubber !tar 'ooler >et $sp. G$C I /II !tage Hg. &emo"al Tower !@9 earing gases To acid plant 'alcine 'alcine 'alcine 'alcine

Block Diagram of Roaster and Gas Cleaning

$i4.r1" lock diagram of &oaster -lant

5.26 BOIL! CI CUIT

oiler circuit is use to generate the steam using the heat which is dissipated from &oaster plant. In oiler, demateriali2ed water is use. This demateriali2ed water is supplied from DM. -lant. Ceeding of water in boiler is control and supplied by an electricG turbo feed pump. 'irculation of boiler water is done by electricGturbo circulation pump through roaster furnace coil, boiler bundles and bundles of guide pipe. $#cess steam in e#ported to leaching plant. In case of power failure or any emergency turbo feedGturbo circulation pump may be run with the help of generated steam to feed the water in boiler drum and water can be circulated in cooling coils and boiler bundles. In boiler water following "alues are maintained. -h )lkalinity Hardness 'hloride !ulphite -hosphate !tandard 31.8 911ppm ?il ?il 31ppm 91ppm Minimum 6.1 + + + 8ppm 31ppm Ma#imum 30.1 811ppm ?il 81ppm + +

'hemical i.e. sodium sulphite, trisodium phosphate caustic soda are prepared and inDected in Derator discharge through I dosing pump.

5.>6 ACID PLANT"

-roduction of sulphuric acid in acid plant 3 and 9 is done. !ulphuric acid thus produced is stored in acid storage tank labeled as ), acid is stored in acid storage tank D/$. The acid is supplied to the leaching plant or in tanks ), , ' of acid plant ?o.9 through a transfer pump of capacity 3111MT, 3111MT and 3811MT respecti"ely. Cinally gases are discharged through chimney to atmosphere. and ' product sulphuric

!@9 earing Eases

Drying Tower

!@9 lower

Heat e#changer

I 'on"erter I<

II

Heat e#changer

III

I-)T

Heat e#changer )cid storage tank

Cinal absorption tower

!tack
$i4.r1" lock diagram of acid plant

Minimum 4=I acid concentration is maintained in acid storage tanks. )cid of supply tank ),

' is analy2ed and analysis is recorded in register ?o. Z!DG&/)G&eg.1=. If any how the acid concentration is found below 4=I in any supply tanks, this acid is recycled back to acid circulation tank to build up the concentration to 4=I min. or raise the concentration by mi#ing with fresh product acid of higher concentration or alternati"ely this acid is used for internal consumption in leaching, &T- or DM plant Pr1-H1a,1rA+ The preheater is to generate flue gases heating the catalyst mass up to 058 oc %min(, when starting the plant after shut down. Hot air is obtained by burning LD@ with air in combustion chamber of preheater. LD@ is supplied to the burner, where combustion takes place and air is heated. The air for atomi2ation and combustion is pro"ided by combustion blower. )ir for dilution is pro"ided by dilution blower. The hot air is passed through the tube of heat e#changer whereas the sulphur dio#ide bearing gases passes on shall side and get heated. The fuel gas is "ented to atmosphere through the stack.

5.&6 L!ACHIN% ' PU I$ICATION PLANT

Leaching is selecti"e dissolution of ore mineralsGo#ides, alkalis or solution of other reagent according to condition adDusted in a manner to lea"e ma# gangue in soluble residue. 'alcine come in hopper with the help of bucket ele"ator. Crom hopper calcine is coming to roller con"eyor through a rotatry "al"e. y adDusting speed of rotatry "al"e calcine rate can be increased or decreased. The calcine if in e#cess can be stored in silos. The a"erage rate of calcine consumption is 33 MTG hr., whereas rate of solution supplied is 41m0Ghr. This corresponds to 3;1+381 MT of Zinc ingots. The department consists of following sectionsA 3. ?eutral leaching 9. acid Leaching 0. -urification

;. &esidual treatment plant 8. cadmium plant N!UT AL L!ACHIN%" The iron leached from fine particles of Zn@.Ce9@0 will be precipitated as hydro#ides in neutral medium according to e.uation. Ce9%!@;(0K0Zn@K0H9@ L 9Ce%@H(0K0Zn!@; The Zn in calcine is present asA ZnO - 63 to 60I Zn!@; H 5 to = I ZnS - 3 to 9I Zn@Ce9@0 H 31I In first stage of neutral leaching solution will be slightly acidic/ -H is 9.6 to 0.9.!o main e.uationA Me@K H9!@; L Me!@;KH9@ :h1r1 M1D Zn, 'u, ?i, 'o, Mg, -d. The -H solution discharged after completion of leaching is ;.8 / at that -H acidity is negligible. ACID L!ACHIN%" This is carried in carriers ha"ing capacity of ;8 m0.The underflow from neutral leaching containing dissol"ed Zn@ / Zn@.Ce9'@0 is leached with spent electrolyte to -H of 9.6. )lternate carriers are pro"ided with heating coil through which steam is passed. &eaction time is 8 hr. most soluble o#ide go into solution. The o"erflow containing 01+;1 E-L of Zn is sent to neutral leaching. ,nderflow is pumped to two drum filters. PU I$ICATION" -urification of Zinc sulphate is necessary as certain elements e"en if amounting to milligrams per liter may causeA+

3. Hydrogen e"olution and dissolution of Zinc by reducing impurities CeKK, 'o, ?i, )s etc. 9. Zinc is electro positi"e to ordinary metal like copper, iron, cadmium etc. therefore during electrolysis these elements coil tends to deposit along with 2inc, affecting the purity of the final product and current efficient. Prin/i871" :eeping temperature to 61 to 68 degree ', the clear o"erflow from the natural thickener is fed into the purification stage. The purpose of this stage is to remo"e base metal impurities like copper, cadmium, nickel etc. which are harmful to electrolysis of 2inc. )ll these elements are remo"ed by precipitation with the help of Zinc dust. Zinc being placed higher then all the elements in the electromechanical series of elements, displaces them from solution of sulphates as per the following reactionA Zn K Mn!@; Zn!@; K Mppt

)lso addition of antimony tratarte and copper sulphate speed up the rate of reaction to ensure complete remo"al of impurities.

Leaching 'alcine

@Gf
Thickening *oaosite
,G C

-urification

-urified neutral !olution

?eutrali2ation

)cid leaching
,G C

'd reco"ery

&esidual Treatment Thickning 'd -encil

,GC

*arosite filteration

Zerosite cake to $T$i4.r1" -rocess flow chart of Leaching plant

5.56

!SIDU! T !ATM!NT PLANT

The Zinc ferrite Zn@. Ce9@0 in the acid thickness under flow gets leached in the con"ersion and simultaneously the leached iron is precipitated as Zerosite. Here the section is carried out in there lead or brick line rectors of 011 meter cube capacity each, at a temperature of 48 to 311'. !ome amount of Mn@9 is also added to take care of reducing impurities. In this operation Zinc ferrite is precipitated as comple# known as Zerosite.

The Zerosite slurry from this reaction is settled in the D@&& with county current decantation. Zerosite from the last thickener continues repulped and filtered again to reco"er water soluble Zinc. The cake is subse.uently repulped and pumped in $T- where it is neutrali2ed to6ph and discarded into lagoon . The o"er low from the D@&& contains 61+311 E-L iron is send to neutral leaching.

5.*6 ZINC DUST PLANT

The use of Zinc dust is for internal consumption, use in purification process to remo"e 'u!@ ;, 'd!@;, 'o!@;, ?i!@; in leaching plant. The reaction follows as+ Zn E M1SO&D ZnSO& E M1F Due to higher electropositi"e element, the process of Zn dust in"ol"es the followingA 3. Zn melting 9. Zn "apori2ation 0. 'ondensation ;. -roduction Technology Cor Zn "apori2ation a "oltage of 3111+3311 1' is created with the help of two electrodes, one at top / other at base. It is filled with molten Zn. Cor condensation ?9 gas is being used. The ?9 gas / fi"e particles of Zn dust is being passed ? 9 gas is passed containing fi"e particles of Zn dust. The Zn dust is get at bottom. The body of condenser is made up of mild steel. The separate Zn dust cyclone is being used. )gain to separate Zn dust from ?9 gas it is passed through a bag filter. -roduction rate is about 5+ 5.8MTGday. The pressure of ? 9 gas is about 511 cubic feet. The consumption to produce 3 MT Zn dust is about 698 H 681 :>Ghr.

5.=6 ZINC !L!CT OL#SIS ' M!LTIN%"

$lectrolysis of Zn!@; solution takes place in electrolysis cells with )l as cathode / -b as anode. The reaction can be represented as ZnSO&D Zn2E E SO&2SO& E H2OD H2SO& E GO2 Zn ions migrate towards the cathode and get deposited in form of sheets whereas @9 is gi"en off at anode. )s !@9 ions, this results in formation of !ulphuric )cid. The o#ygen is liberated o#ides the manganous sulphate in solution to Mn@9 which deposit on the anode surface as anode mud which is then cleaned out periodically.

5.<6 SOLUTION COOLIN% ' STO A%!

?eutral electrolyte form purification shall be a"ailable at 51 H =1 1' as hot purification process had adopted for e#pansion the neutral solution is fed direct to atmospheric coolers where direct solution is cooled to 681'. Two coolers ha"e been pro"ided for the purpose of which one would stand by. The HZL has adopted MH)M@? 81 $L$@N elgion design for atmospheric coolers which are being used in nos. of other plants in the world. Zn!@; solution that has to be cooled is taken through main feeder / it is distributed through reinforced polyester pipes on which is stainless steel 035 spraying no22les are fi#ed. )bo"e this, drift eliminated are arranged in two layers in form of layers of -<' wa"es. These wa"es, assembled in panes are easily remo"able through top of coolers. The cooler is fitted with forced draught fan fitted with C&- blades. The fan stock is also made up from C&- / stainless steel grating pro"ides protection to fan inlet. The fan is dri"en pulley / belt by two speed motors. These coolers are used to reduce the temperature from ;91' to 081'. $lectrolysis takes place in lead lines concrete cells which are connected electricity by means of 'u bus bars in series parallel system for flow of current in e#isting cell house. The cells are arranged in ;1 rows. $ach row has 5 cells with 9= )l cathode and 96 lead anodes. )fter e#pansion, each cell will ha"e its own feed system / its own independent discharge of electrolytes.

*. C1n,ra7 :orksho8"

The Zinc smelter, Debari has a central workshop for securing / repairing of different mechanical e.uipments such as pumps, fans, mechanical con"eyors, hoists etc. The central workshop consists of following shopsA 3. Machine shop 9. >elding shop 0. !miting shop ;. >ood shop *.16 MACHIN! SHOP "Machine shop is the biggest shop in all shops it consists of "arious machines. They are+ 3. lathe machine 9. 0. ;. 8. 5. =. 6. 4. 31. 33. Drilling machine !lottering machine !haper machine -unching machine !hearing machine -ower sack saw milling machine Erinding machine Hydraulic -ressure machine -ipe bending / sheet rolling machine

&epairing of many parts is done in central workshop on different machines. *.26 :!LDIN% :O ASHOP reaking parts which are easily weld able are welded in welding workshop. There are two types of welding is done. 3. )rc welding / 9. Eas welding !o two types of sets areA 3. )rc welding set 9. Eas welding set )rc welding is most e#tensi"ely employed method for Doining metal parts where source of heat is electric arc.

Eas welding is done by a combustible gas with air or o#ygen in a concentrate flame at higher temperature. *.>6 SMITH# SHOP In !mithy shop some parts are manufactured which are to be used in different plants main components of this shop areA 3. Curnaces 9. )n"il *.&6 :OOD :O ASHOP In >ood workshop some process happens such as planning, groo"ing, cutting of wood used in different plants on different machines a"ailable in workshop.

*.56 !L!CT ICAL !PAI SHOP The Zinc !melter, Debari has an electrical repair shop. $lectricity is "ery important for an industry without it no work can be performed now a day. !o electrical e.uipments are also used widely in industry. To repair electric material, electrical repair shop is to be used. ACTICITI!S O$ !L!CT ICAL !PAI SHOP "3. @"erhauling / &ewinding of LT motors up to 981 :>. 9. 0. ;. 8. 5. )M' of cooling machine &efrigerators >indow )G' -ackage )G' >ater coolers etc.

0. ;09 lines $- )O definity, tata telecom , -) system 3. contract scheduling , finali2ation and e#ecution 9. -rocurement 0. &esource planning / estimation ;. In-1n,in4 H formulation / specifications of electrical items 8. Technical e"olution of electrical items %tech bids( 5. Handling .uality, assuranceG inspection of incoming materialG spares

=. Sa;1,9 ass.ran/1 H per I$ rules.

y impro"ing the house keeping / all --$Bs so safety e.uipments as

6. )lso associate with working for reduction in spares consumption, in"entory control by e#ploration / reclamation 4. Eeneration of power reports weeklyG monthly / preparation of liability statements.

=. Ins,r.31n,a,ion D18ar,31n,
Zinc smelter instrumentation department analyses, controls and records "arious process parameters and on the basis of these parameters "arious processes are being controlled. Cor ideal process e#ecution, producti"ity and pollution control the instrumentation department plays an e#tremely important role. Here the following parameters are considered for process e#ecution and recording is made and computeri2ed as and when desired. 3. P.n/hin4 C7o/ks" - ,sing these clocks the attendance of all employees and their in and out times are recorded and computeri2ed as well. 9. :1i4h Bri-41" - 'omputeri2ed weigh bridges are used to weigh raw materials and the finished goods ready for dispatch. $lectronics feed machines are used to feed raw materials and chemicals in the plant. 0. A.,o3a,i/ Cas,in4 Ma/hin1 an- B.n-71 Ma/hin1s" - ,sing these machines 2inc ingots are casted automatically and are bundled in lots. ;. $7o2 M1as.r131n," - >ater meters, &ota meters magnetic flow meters, differential flow transmitters and "erte# flow meters are the "arious de"ices implemented to carry out flow measurements. 'ontrolling is done through controller and control "al"e. 8. Pr1ss.r1 M1as.r131n," - Cor the filled indication pressure gauges and manometers are used. -rocesses are being controlled by pressure transmitters, recorders, indicators, controllers and control "al"es. 5. L1017 M1as.r131n,s" - Cor le"el control indication and recording of "arious process elements the de"ices basically used are le"el switches. Le"el transmitters and ultrasonic transmitters. =. T1381ra,.r1 M1as.r131n," - Cor temperature controlling, recording, indication and alarming temperature recorders, indicators, controllers and pyrometers are used. )s primary

sensors thermocouples and &TD are also used with these temperature recorders, indicators, controllers and pyrometers. 6. Ph /on-./,i0i,9I A/i- Con/1n,ra,ion an- %as ana79sis" - ,sing automatic -h channel analy2er, concentration analy2er and conducti"ity analy2er the abo"e mentioned parameters are automatically controlled recordedZinc !melter, Debari instrumentation, department deals with maintenance, calibration, repairing, erection and commissioning. Maintenance and calibration work is done according to the norms specified by I!@ 4113 and I!@ 3;113 standards. Cor maintenance , 'alibration and repairing sufficient e.uipments are a"ailable with the instrument department. They are as followsA 3( )"ometers 9( Milliampere and milli"olt sources and measuring instruments 0( <ariable ac+dc power supplies ;( -ortable temperature indicators 8( &esistance bo#es 5( '&@ =( Cre.uency generators 6( Heart communicators 4( Clow calibrator 31( 'onducti"ity calibrators 33( Dead >eight Testers Instrumentation department is fragmented into three sectionsA+ 16 C!NT AL this section. 26 OAST! ACID S!CTION" )cid H I, )cid H II, roaster H I, roaster H II, DM plant and !PAI SHOP" In this section indenting, material inspection and typical repairing are done. Moor cake plant and 1;;7.1n, ,r1a,31n, 87an, are also super"ised by

compressor house are super"ised by this section. >6 L!ACHIN% AND PU I$ICATION S!CTION" >eigh bridge, Zinc Dust, neutro leaching, purification, DE set 2inc electrolysis are super"ised by this section.

PROJECT: STUD O! P"O#"A$$ABL% LO#IC CONT"OLL%"S

1. In,ro-./,ion"
) 8ro4ra33a@71 7o4i/ /on,ro771r %-L'( is an industrial computer control system that continuously monitors the state of input de"ices and makes decisions based upon a custom program, to control the state of de"ices connected as outputs. They are specially designed architecture in both their central units %the -L' itself( and their interfacing circuitry to field de"ices %inputGoutput connections to the real world(. These de"ices, also called programmable controllers or PLCs are the hub of many manufacturing processes. These are solid+state members of the computer family, using integrated circuits instead of electromechanical de"ices to implement control functions. They are capable of storing instructions, such communication, to as se.uencing, timing, counting, arithmetic, data and manipulation, and control industrial machines processes. Cigure 3+3 illustrates a

conceptual diagram of a -L' application.

Process or Machines

Ceedback from sensorsGswitches

Measure

Control

'onnections to

actuators

Field Inputs

Programmable Controller
Field Outputs

$i4.r1 1-1. -L' conceptual application diagram. )lmost any production line, machine function or process can be automated using a -L'. The speed and accuracy of the operation can be greatly enhanced using this type of control system. ut the biggest benefit in using a -L' is the ability to change and interfere with the operation or process while collecting and communicating "ital information. ,nlike general+purpose computers, the -L' is designed for multiple inputs and output arrangements, e#tended temperature ranges, immunity to electrical noise, and resistance to "ibration and impact. -rograms to control machine operation are typically stored in battery+ backed or non+"olatile memory. ) -L' is an e#ample of a real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result.

2. N11- o; PLC"
17a9 an- i,s -isa-0an,a41s" Modern control systems still include relays, but these are rarely used for logic. ) relay is an 171/,ri/a779 o81ra,1- s2i,/h. 'urrent flowing through the coil of the relay creates a magnetic field which attracts a le"er and changes the switch contacts. The coil current can be on or off so relays ha"e two switch positions and they are double throw %changeo"er( switches. &elay pro"ides electrical isolation between two circuits. The coil of a relay passes a relati"ely large current, typically 01m) for a 39< relay, but it can be as much as 311m) for relays designed to operate from lower "oltages.

&elays are usually !-DT or D-DT but they can ha"e many more sets of switch contacts, for e#ample relays with ; sets of changeo"er contacts are readily a"ailable. >hen a relay is used to switch a large amount of electrical power through its contacts, it is assigned by a special nameA /on,a/,or. 'ontactors typically ha"e multiple contacts. -erhaps the most common industrial use for contactors is the control of electric motors.

) basic contactor will ha"e a coil input %dri"en by either an )' or D' supply depending on the contactor design(. The coil may be energi2ed at the same "oltage as the motor, or may be separately controlled with a lower coil "oltage, at present they are better suited to control by programmable controllers%but not for de"eloping logic( and other lower+"oltage de"ices. 'ontactors range from a breaking current of se"eral amps and 9; < dc to thousands of amps and many kilo"olts. Disadvantages: &elays cannot switch rapidly %e#cept reed relays(, transistors can switch many times per second. &elays use more power due to the current flowing through their coil. &elays re.uire more current than many I's can pro"ide, so a low power transistor may be needed to switch the current for the relayJs coil. efore the -L', control, se.uencing, and safety interlock logic for manufacturing automobiles was accomplished using hundreds or thousands of relays, timers, and drum se.uencers and dedicated closed+loop controllers. The process for updating such facilities was "ery time consuming and e#pensi"e, as the relay systems needed to be rewired by skilled electricians . So the primary goal of introducing -L' was to eliminate the high costs associated with infle#ible, relay+controlled systems. The specifications re.uired a solid+state system with computer fle#ibility a@71 ,o %3( sur"i"e in an industrial en"ironment, %9( be easily programmed and maintained by plant engineers and technicians, and %0( be reusable. Hence the -rogrammable logic control came into picture which fulfills all re.uirements, i.e. reusability, e#pandability, programmability, and ease of use in an industrial en"ironment.

>. PLC 8as, an- 8r1s1n," >.16 His,or9 o; 87/"

The first -L's offered relay functionality, thus replacing the original hardwired r17a9 7o4i/, which used electrically operated de"ices to mechanically switch electrical circuits. The first programmable controllers were more or less Dust relay replacers. Their primary function was to perform the se.uential operations that were pre"iously implemented with relays. These operations

included @?G@CC control of machines and processes that re.uired repetiti"e operations, such as transfer lines and grinding and boring machines. !ome of the feature of first introduced -lc wereA ) typical unit housing a '-, and IG@ was roughly the si2e of a 34N tele"ision set. Through the

3461s and early 3441s, modular -L's continued to shrink their si2e while increasing in capabilities and performance. + communications protocol allowed -L's to communicate o"er some specific standard cabling. + the controller does not know the position of the output de"ice during the control se.uence. + e"en simple motion control re.uired an e#pensi"e -L' module so cost was much higher.. + only &elay Ladder logic programming was supported. )lthough -L' functions, such as speed of operation, types of interfaces, and data+processing capabilities, ha"e impro"ed throughout the years, but they are simple to use and maintain.

>.2 Th1 8r1s1n, s,a,1

-L's are also now well+e.uipped to replace stand+alone process controllers in many applications, due to their ability to perform functions of motion control, data ac.uisition, &T, %remote telemetry unit( and e"en some integrated HMI %human machine interface( functions. key characteristics of plc at present areA + smaller -L's ha"e been introduced in nano and micro classes that offer features e.ui"alent to larger -L's. These are capable of motion control, remote connecti"ity and more. + the serial communications remain popular and reliable, but now $thernet is fast becoming the popular communication media with ad"antages of network speed, ease of use, built+in communications setups etc. + high+speed counting capabilities and high+fre.uency pulse outputs built into the controller, making them a suitable solution for both open / closed+loop control. + almost e"ery -L' now+a+days can support two graphical and two te#tual -L' programming language standardsA Ladder logic %graphical(. Cunction block diagram %graphical(. !tructured te#t %te#tual(. Instruction list %te#tual(.

The latest technology gi"es the -L' a faster, more powerful processor with more memory at less cost. These ad"ances ha"e also allowed the -L' to e#pand area of command and take on new tasks like communications, data manipulation and high+speed motion without gi"ing up the rugged and reliable performance e#pected from industrial control e.uipment.

&. A-0an,a41s o; PLC

Inh1r1n, $1a,.r1s !olid+state components -rogrammable memory !mall si2e Microprocessor+based B1n1;i,s P High reliability P !implifies changes / Cle#ible control P Minimal space re.uirements P 'ommunication capability P Higher le"el of performance P Higher .uality products P Multifunctional capability P $liminate hardware P $asily changed presets P &educe hardwareGwiring cost P &educe space re.uirements P Installation fle#ibility P $asily installed P &educes hardware cost P $#pandability P 'ontrols a "ariety of de"ices P $liminates customi2ed control P $liminate long wireGconduit runs P &educe troubleshooting time P !ignal proper operation P ?eat appearance of control panel P $asily maintained

!oftware timersGcounters !oftware control relays Modular architecture

<ariety of IG@ interfaces &emote IG@ stations Diagnostic indicators Modular IG@ interface

P $asily wired Quick IG@ disconnects !ystem "ariables P !er"ice without disturbing wiring P ,seful managementGmaintenance stored in memory data P 'an be output in report form

5. PLC ;1a,.r1s"
The following list describes some latest -L' hardware enhancementsA P Caster scan times are achie"ed using new ad"anced microprocessor and electronic technology. P !mall, low+cost -L's which can replace four to ten relays ha"e more power than their predecessor, the simple relay replacer. P High+density inputGoutput %IG@( systems pro"ide space+efficient interfaces at low cost. P Intelligent, microprocessor+based IG@ interface can pro"ide distributed processing. !ome of the interfaces include ')?bus, fieldbus, )!'II communication, positioning, host computer, and language modules %e.g., )!I', -ascal(. P Mechanical design impro"ements include rugged inputGoutput enclosure and inputGoutput systems that makes the terminal an integral unit. P !pecial interfaces allow certain de"ices to be connected directly to the controller. !ome of them are thermocouples, strain gauges, and fast+response inputs. )ll of these hardware enhancements ha"e led to the de"elopment of programmable controller families like the one shown in Cigure Like hardware ad"ances, software ad"ances, ha"e led to more powerful -L'sA P -L's now support obDect+oriented programming tools and multiple languages based on the I$' 3303+0 standard. P $"en small -L's ha"e powerful instructions, which e#tend the area of application for these small controllers.

P High+le"el languages, such as )!I' and ', is present in some controllersB modules to pro"ide greater programming fle#ibility when communicating with peripheral de"ices and manipulating data. P )d"anced functional block instructions for ladder diagram instruction sets, pro"ide enhanced software capability using simple programming commands. P Impro"ed diagnostics and fault detection facility to include machine diagnostics along with simple system diagnostics, which diagnose failures or malfunctions of the controlled machine or process also diagnosing controller malfunctions.. Impro"ed and simplified data handling and manipulation instructions to accommodate comple# control and data ac.uisition applications that in"ol"e storage, tracking, and retrie"al of large amounts of data.

*.In,1rna7 ar/hi,1/,.r1 o; PLC "

The basic internal architecture of a -L' is shown in figure. It consists of a central processing unit %'-,( containing the system microprocessor, memory, and inputGoutput circuitry. The CPU controls and processes all the operations within the -L'. It is supplied with a clock with a fre.uency of typically between 3 and 6 MH2. This fre.uency determines the operating speed of the -L' and pro"ides the timing and synchroni2ation for all elements in the system.

$i4.r1 " Internal Architecture of PLC

The information within the -L' is carried by means of digital signals. The internal paths along which digital signals flow are called buses. In the physical sense, a bus is Dust a number of conductors along which electrical signals can flow. It might be tracks on a printed circuit board or wires in a ribbon cable. The '-, uses the data bus for sending data between the constituent elements, the address bus to send the addresses of locations for accessing stored data and the control bus for signals relating to internal control actions. The system bus is used for communications between the inputGoutput ports and the inputGoutput unit.

*.16 Th1 CPU

The internal structure of the '-, depends on the microprocessor concerned. In general they ha"eA )n arithmetic and logic unit %)L,( which is responsible for data manipulation and carrying out arithmetic operations of addition and subtraction and logic operations of )?D, @&, ?@T and $O'L,!I<$+@&. Memory, termed registers, located within the microprocessor and used to store information in"ol"ed in program e#ecution. ) control unit which is used to control the timing of operations.

*.26 Th1 @.s1s

The buses are the paths used for communication within the -L'. The information is transmitted in binary form, i.e. as a group of bits %a byte or a word( with a bit being a binary digit of 3 or 1, i.e. onGoff states. $ach of the bits is communicated simultaneously along its own parallel wire. The system has four busesA The data bus carries the data used in the processing carried out by the '-,. ) microprocessor termed as being 6+bit has an internal data bus which can handle 6+bit numbers. It can thus perform operations between 6+bit numbers and deli"er results as 6+bit "alues. The address bus is used to carry the addresses of memory locations. !o that data stored at a particular location can be accessed by the '-, either to read data located there or put, i.e. write, data there. It is the address bus which carries the information indicating which

address is to be accessed. If the address bus consists of 6 lines, the number of 6+bit words, and hence number of distinct addresses, is 9 6 R 985. >ith 35 address lines, 58 805 addresses are possible. The control bus carries the signals used by the '-, for control, e.g. to inform memory de"ices whether they are to recei"e data from an input or output data and to carry timing signals used to synchroni2e actions. The system bus is used for communications between the inputGoutput ports and the inputGoutput unit.

*.>6 M13or9
There are se"eral memory elements in a -L' systemA !ystem read-only-memory %R M! to gi"e permanent storage for the operating system and fi#ed data used by the '-,. Random-access memory "RAM! for the userBs program and for data. This is where information is stored on the status of input and output de"ices and the "alues of timers and counters and other internal de"ices. The data &)M is sometimes referred to as a data table or register table. -art of this memory, i.e. a block of addresses, will be set aside for input and output addresses and the states of those inputs and outputs. -art will be set aside for preset data and part for storing counter "alues, timer "alues, etc. -ossibly, as a bolt+on e#tra module, erasable and #rogrammable read$only$memory "%PR M! for &@Ms that can be programmed and then the program made permanent. The programs and data in &)M can be changed by the user. )ll -L's will ha"e some amount of &)M to store programs that ha"e been de"eloped by the user and program data. Howe"er, to pre"ent the loss of programs when the power supply is switched off, a battery is used in the -L' to maintain the &)M contents for a period of time. )fter a program has been de"eloped in &)M it may be loaded into an $-&@M memory chip, often a bolt+on module to the -L', and so made permanent. In addition there are temporary buffer stores for the inputGoutput channels.

*.&6 In8.,Jo.,8., .ni,

The inputGoutput unit pro"ides the interface between the system and the outside world, allowing for connections to be made through inputGoutput channels to input de"ices such as sensors and output de"ices such as motors and solenoids. It is also through the inputGoutput unit that programs are

entered from a program panel. $"ery inputGoutput point has a uni.ue address which can be used by the '-,. The inputGoutput channels pro"ide isolation and signal conditioning functions so that sensors and actuators can often be directly connected to them without the need for other circuitry. $lectrical isolation from the e#ternal world is usually by means of optoisolator %the term o#tocou#ler is also often used(. Cigure8 shows the principle of an optoisolator. >hen a digital pulse passes through the light+emitting diode, a pulse of infrared radiation is produced. This pulse is detected by the phototransistor and gi"es rise to a "oltage in that circuit. The gap between the light+ emitting diode and the phototransistor gi"es electrical isolation but the arrangement still allows for a digital pulse in one circuit to gi"e rise to a digital pulse in another circuit.
$i4.r1 #toisolator

The digital signal that is generally compatible with the microprocessor in the -L' is 8 < d.c. Howe"er, signal conditioning in the input channel, with isolation, enables a wide range of input signals to be supplied to it. ) range of inputs might be a"ailable with a larger -L', e.g. 8 <, 9; <, 331 < and 9;1 < digitalGdiscrete, i.e. onSoff, signals %Cigure 5(. ) small -L' is likely to ha"e Dust one form of input, e.g. 9; <.

$i4.r1" In#ut Levels The output from the inputGoutput unit will be digital with a le"el of 8 <. Howe"er, after signal conditioning with relays, transistors or triacs, the output from the output channel might be a 9; <, 311 m) switching signal, a d.c. "oltage of 331 <, 3 ) or perhaps 9;1 <, 3 ) a.c., or 9;1 <, 9 ) a.c., from a triac output channel %Cigure =(. >ith a small -L', all the outputs might be of one type, e.g. 9;1 < a.c., 3 ). >ith modular -L's, howe"er, a range of outputs can be accommodated by selection of the modules to be used.

$i4.r1 @utputs are specified as being of relay type, transistor type or triac type.

ut#ut levels

>ith the relay type, the signal from the -L' output is used to operate a relay and is able to switch currents of the order of a few amperes in an e#ternal circuit. The relay not only allows small currents to switch much larger currents but also isolates the -L' from the e#ternal circuit. &elays are, howe"er, relati"ely slow to operate. &elay outputs are suitable for a.c. and d.c. switching. They can withstand high surge currents and "oltage transients.

The transistor type of output uses a transistor to switch current through the e#ternal circuit. This gi"es a considerably faster switching action. It is, howe"er, strictly for d.c. switching and is destroyed by o"er current and high re"erse "oltage. )s a protection, either a fuse or built+in electronic protections are used. @ptoisolators are used to pro"ide isolation.

Triac o.,8.,s, with optoisolator for isolation, can be used to control e#ternal loads which are connected to the a.c. power supply. It is strictly for a.c. operation and is "ery easily destroyed by o"er current. Cuses are "irtually always included to protect such outputs.

*.56 T981s o; In8., an- o.,8.,s "

5.8.3( Discrete in#ut: ) discrete input also referred to as a digital input, is an input that is either in an @? or @CC condition.

5.8.9( Analog In#ut: )n analog input is an input signal that has a continuous signal. Typical analog inputs may "ary from 1 to 91 milliamps, ; to 91 milliamps, or 1 to 31 "olts. In the following e#ample, a le"el transmitter monitors the le"el of li.uid in a tank. Depending on the le"el transmitter, the signal to

the -L' can either increase or decrease as the le"el increases or decreases.

5.8.0( Discrete ut#ut: ) discrete output is an output that is either in an @? or @CC condition. !olenoids, contactor coils, and lamps are e#amples of actuator de"ices connected to discrete outputs. Discrete outputs may also be referred to as digital outputs. In the following e#ample, a lamp can be turned on or off by the -L' output it is connected to.

5.8.;( Analog ut#ut: )n analog output is an output signal that has a continuous signal. The output may be as simple as a 1+31 <D' le"el that dri"es an analog meter. $#amples of analog meter outputs are speed, weight, and temperature. The output signal may also be used on more comple# applications such as a current+to pneumatic transducer that controls an air+operated flow+control "al"e.

*.*6 In8.,Jo.,8., ,1r3ino7o49"

5.5.3( Sensors: ) sensor is a de"ice that con"erts a physical condition into an electrical signal for use by the -L'. !ensors are connected to the input of a -L'. These act as input to -L'. 1. M1/hani/a7 s2i,/h1s" ) mechanical switch generates an on+off signal or signals as a result of some mechanical input

causing the switch to open or close. These contact switches are a"ailable as normally open and normally closed They are used as motion limit switches and part present detectors.

9. Pro?i3i,9 s2i,/h
-ro#imity switches are used to detect the presence of an item without making contact with it. There are a number of forms of such switches, some being only suitable for metallic obDects. The eddy current type of pro#imity switch has a coil which is energi2ed by a constant alternating current and produces a constant alternating magnetic field. >hen a metallic obDect is close to it, eddy currents are induced in it >. 11- s2i,/h &eed switch has two non touching springy strips of ferromagnetic material enclosed in a plastic case. >hen a magnet or current+carrying coil is brought close to the switch, the strips attract and switch closed. &. Ca8a/i,i01 S1nsors These sensors can detect metallic or non metallic material by generating signal according dielectric change or we can say capaciti"e change 5. O8,i/a7 S1nsors" @ptical sensors re.uire both a light source %emitter( and detector. $mitters will produce light beams in the "isible and in"isible spectrums using L$Ds and laser diodes. Detectors are mostly built with photodiodes or phototransistors. The emitter and detector are positioned so that an obDect will block or reflect a beam when presentT according to which signal is generated. *. U7,rasoni/ S1nsors" )n ultrasonic sensor emits a sound abo"e the normal hearing threshold of 35 :H2. The time that is re.uired for the sound to tra"el to the target and reflect back is proportional to the distance to the target. =. T1381ra,.r1 s1nsors" ) temperature sensor can be used to pro"ide an onHoff signal when a particular temperature is reached. Cor e.g. switching of a bimetallic strip when a particular temperature is reached. )nother and most important e#amples of temperature sensor are &TD and thermocouple. to its

&TD %&esistance Temperature Detectors(A These de"ices ha"e positi"e temperature coefficients that cause resistance to increase linearly with temperature. ) platinum &TD might ha"e a resistance of 311 ohms at 1o', which will increase by 1.; ohmsGU'. The total resistance of an &TD might double o"er the temperature range. Mostly their ma# temperature sensing rage "aries from +911o' to ma#. of 581o'. ThermocoupleA The thermocouple consists of two dissimilar wires ) and forming a Dunction. In

a thermocouple, the two metals are Doined together at Dunctions with different temperatures. This temperature differential creates a "oltage across the thermocoupleVa phenomenon known as the !eebeck effect. Temperature &3, the hot 'unction, is the temperature being measured, while &9, the cold 'unction, is the reference temperature. )s temperature &3 increases, the "oltage differential %emf( between materials ) and 5.5.9( Actuators: )ctuators dri"e motions in mechanical systems. Most often this is by con"erting electrical energy into some form of mechanical motion. These act as output to -L'. 1. So71noi-" !olenoids are the most common actuator components. The basic principle of operation is there is a mo"ing ferrous core %a piston( that will mo"e inside wire coil when the coil is e#cited. ?ormally the piston is held outside the coil by a spring. )pplications of solenoid include pneumatic "alues and car door openers. 2. 17a9" !olenoids form the basis of a number of output control actuators. !uch an actuator is the relay. >hen the output from the -L' is switched on, the solenoid magnetic field is produced and pulls on the contacts and so closes a switch or switches Thus the relay might be used to switch on the current to a motor. >. Ca701s" The flow of fluids and air can be controlled with solenoid controlled "al"es. ) solenoid controlled "al"e is shown in figure. The solenoid is mounted on the side. >hen it is actuated, it will dri"e the central spool right to close the inlet path %in figure(. In unactuated position, it will return back to original position by the spring to close path ). increases in proportion to the temperature.

$i4.r1" (olenoid valve &. Mo,ors" Motors are common actuators, but for logical control applications their properties are not that important. Typically logical control of motors consists of switching low current motors directly with a -L', or for more powerful motors using a relay or motor starter. 5. S,1881r 3o,ors" The ste##er or ste##ing produces rotation through e.ual angles, the so+termed ste#s, for each digital $i4.r1A (te##er motor )ith * #oles pulse supplied to its input. If it is used to dri"e a continuous belt, it can be used to gi"e accurate linear positioning. !uch a motor is used with computer printers, robots, machine tools and a wide range of instruments where accurate positioning is re.uired. motor is a motor that

thers: There are many other types of actuators including those on the brief list below.

H1a,1rs + They are often controlled with a relay and turned on and off to maintain a temperature within a range. Li4h,s + Lights are used on almost all machines to indicate the machine state and pro"ide feedback to the operator. Most lights are low current and are connected directly to the -L'. Sir1nsJHorns + !irens or horns can be useful for unattended or dangerous machines to make conditions well known. These can often be connected directly to the -L'.

5. So.r/in4 an- sinkin4

The terms sourcing and sinking are used to describe the way in which d.c. de"ices are connected to a -L'. >ith sourcing, using the con"entional current flow direction as from positi"e to negati"e, an input de"ice recei"es current from the input module, i.e. the input module is the source of the current %Cigure 6%a((. If the current flows from the output module to an output load then the output module is referred to as sourcing %Cigure 6%b((.

$i4.r1 <" (ourcing >ith sinking, using the con"entional current flow direction as from positi"e to negati"e, an input de"ice supplies current to the input module, i.e. the input module is the sink for the current %Cigure 4%a((. If the current flows to the output module from an output load then the output module is referred to as sinking %Cigure 4%b((

$i4.r1 ) (in+ing

=. Th1 PLC s9s,13 Har-2ar1"

Typically a -L' system has the basic functional components of processor unit, memory, power supply unit, inputGoutput interface section, communications interface and the programming de"ice. Cigure shows the basic arrangement.

1. 2. The 8ro/1ssor .ni,

T&mers
Co'nters

or

central processing unit %'-,! is the unit containing the microprocessor and this interprets $i4.r1 " The -L' system the input signals and carries out the control actions, according to the program stored in its memory, communicating the decisions as action signals to the outputs. >. The 8o21r s.8879 unit is needed to con"ert the mains a.c. "oltage to the low d.c. "oltage %8 <( necessary for the processor and the circuits in the input and output interface modules. &. The 8ro4ra33in4 -10i/1 is used to enter the re.uired program into the memory of the processor. The program is de"eloped in the de"ice and then transferred to the memory unit of the -L'. 5. The 313or9 .ni, is where the program is stored that is to be used for the control actions to be e#ercised by the microprocessor and data stored from the input for processing and for the output for outputting. *. The in8., an- o.,8., s1/,ions are where the processor recei"es information from e#ternal de"ices and communicates information to e#ternal de"ices. The inputs might thus be from switches or other sensors such as photo+electric cells, temperature sensors, or flow sensors, etc. The outputs might be to motor starter coils, solenoid "al"es, etc. Input and output de"ices can be classified as gi"ing signals which are discrete, digital or analogue. =. The /o33.ni/a,ions in,1r;a/1 is used to recei"e and transmit data on communication networks from or to other remote -L's %Cigure 0(. It is concerned with such actions as de"ice "erification, data ac.uisition, synchroni2ation between user applications and connection management. <. There are four maDor types of Ti31rsK on$delay timer +set the output after a set delay when the logic has been true pre"iously but turn off immediately, for off$delay timer it is "ice+

"ersa. ) retentive timer will sum all of the on or off time for a timer, e"en if the timer ne"er finished. ) nonretentive timer will start timing the delay from 2ero each time. ). There are two basic Co.n,1r typesA count$u# and count$do)n. >hen the input to a count+ up counter goes high %true( the accumulator "alue will increase by 3. If the accumulator "alue reaches the preset "alue the counter bit will be set. Cor count+down counting I decree by one until preset "alue is reached to set counter.

<. Prin/i871 o; O81ra,ion"

) programmable controller consists of two basic sectionsT the central processing unit / the inputGoutput interface system. The operation of a programmable controller is relati"ely simple. The in8.,Jo.,8., 5IJO6 s9s,13 is physically connected to the field de"ices that are encountered in the machine or that are used in the control of a process. These field de"ices may be discrete or analog inputGoutput de"ices, such as limit switches, pressure transducers, push buttons, motor starters, solenoids, etc. The IG@ interfaces pro"ide the connection between the '-, and the information pro"iders %inputs( and controllable de"ices %outputs(. During its operation, the '-, completes three processesA %3( it r1a-s, or accepts, the input data from the field de"ices "ia the input interfaces, %9( it 1?1/.,1s, or performs, the control program stored in the memory system, and %0( it 2ri,1s, or updates, the output de"ices "ia the output interfaces. This process of se.uentially reading the inputs, e#ecuting the program in memory, and updating the outputs is known as s/annin4. The inputGoutput system forms the in,1r;a/1 by which field de"ices are connected to the controller The main purpose of the interface is to condition the "arious signals recei"ed from or sent to e#ternal field de"ices. Incoming signals from sensors %e.g., push buttons, limit switches, analog sensors, selector switches, and thumbwheel switches( are wired to terminals on the input interfaces. De"ices that will be controlled, like motor starters, solenoid "al"es, pilot lights, and position "al"es, are connected to the terminals of the output interfaces. The system 8o21r s.8879 pro"ides all the "oltages re.uired for the proper operation of the "arious central processing unit sections.

). PLCs 01rs.s O,h1r T981s o; Con,ro7s"

) -L' is not the only choice for controlling a process. !ticking with only basic relays may be of a benefit depending upon our application. )lso the -L' "s. -' debate has been going on for a long time. More often though it doesnJt come down to an one sided situation but in"ol"es a mi# of technologies. 1. PLC vs. Relay:

In the early times of programming -L's it was still .uestionable if a -L' was necessary o"er Dust relay control. >ith -L' prices going down, si2e shrinking, and performance of -L's impro"ing o"er the years this has become less of a battle. Fet the designer has to ask themsel"es if a -L' is really o"erkill for their application. 2. PLC vs. Dedicated Controller:

) dedicated controller is a single instrument that is dedicated to controlling one parameter such as a -ID controller measuring a temperature for heating control. They ha"e the ad"antages of an all in one package, typically with display and buttons. This can be a "ery good thing to use in simple applications. ) -L' these days can compete price wise and functionally with these controllers especially if more than one controller is needed. -L's offer a greater degree of fle#ibility too because the can be programmed to handle all sorts of different scenarios. >. PLC vs. PC "Personal Com#uters!:

The -L' "s. -' debate has been going on for years. They both ha"e their pros and cons. >hat often happens is that the two are used for their strengths in different parts of the factory.

12. A-0an/131n,s in PLC"

1. Ar,i;i/ia7 In,177i41n/1"
)rtificial intelligence means make a system able to take decision according to the action being performed. The software programs that form an )I system are de"eloped using the knowledge of e#perts in the field where the system will be applied. )I techni.ues can be implemented through a -L'+based process control system. These techni.ues will define the methods for implementing )I into the process. The result will be a system that can successfully diagnose, control, and predict outcomes based on resident knowledge and program sophistication.

In )I system %see figure(, it must recei"e all information about system maintenance, faults along with their probable causes and possible solutions etc. for de"eloping database. )ccording to this database and predefined rules for go"erning process, )I system maintain the process regular and generate the possible cause of failure, its solution, method to reduce loss or e"en generate new rule for maintaining the process regular indicating the with minimum effect on production .uantity / .uality after indication of the failure. )pplying )I techni.ues to a control system usually in"ol"es adding hardware and software to the system. The comple#ity of the )I program "aries depending on how much fault detection is desired.

Data,ase:
Knowledge information

Feedbac" Information

(nowledge Ac)'&s&t&on

Inference %ng&neControl Strateg ! solution

Act&on Taken

%ng&neer or %*+ert

User

$i4.r1" )rtificial Intelligence system

2.

$.BB9 Lo4i/

$.BB9 7o4i/ is a branch of artificial intelligence that deals with reasoning algorithms used to match human thinking and decision making in machines, and for the information that canJt be represented in binary form. Cu22y logic associates a 4ra-1, or level, with a data range, gi"ing it a "alue of 3 at its ma#imum and 1 at its minimum. Cor e#ample, the statement Mthe air feels coolN is not a discrete statement. In the case of the cool air, a -L' with fu22y logic capabilities would interpret both the le"el of coolness and its relationship to warmth to assure that McoolN means somewhere between hot and cold. Cor logic de"elopment "arious rules are de"eloped taking those components for which the logic has to be de"eloped. )ccording to them the controller performs the task of maintaining the temperature.

>.

H.3an-Ma/hin1 In,1r;a/1"

) Human-Machine nter!ace or HM is the apparatus which presents process data to a human operator, and through which the human operator controls the process. )n HMI is usually linked to the !')D) systemJs databases and software programs, to pro"ide trending, diagnostic data, and management information such as scheduled maintenance procedures, logistic information, detailed schematics for a particular sensor or machine, and e#pert+system troubleshooting guides. The HMI system usually presents the information to the operating personnel graphically, in the form of a mimic diagram. This means that the operator can see a schematic representation of the plant being controlled. $or 1?a3871, a picture of a pump connected to a pipe can show the operator that the pump is running and how much fluid it is pumping through the pipe at the moment. The operator can then switch the pump off. The HMI software will show the flow rate of the fluid in the pipe decrease in real time. Mimic diagrams may consist of line graphics and schematic symbols to represent process elements, or may consist of digital photographs of the process e.uipment o"erlain with animated symbols.

&.

N1,2orkin4"

>hen there is huge amount of data present then sometime processor scan time get affected worst consuming large amount of memory and complicating the program. !o, L)? configuration, in which all data is passed to a host computer that performs all data processing eliminates these problems. )lso instead of single controller se"eral controller may work together or simultaneously, distributing data e"enly through network. To use the distributed processing approach, a local area network and the -L's attached to it must pro"ide the following functionsA P communication between programmable controllers P upload capability to a host computer from any -L' P download capability from a host computer to any -L' P readingGwriting of IG@ "alues and registers to any -L' P monitoring of -L' status and control of -L' operation

1>. Dis,ri@.,1- Con,ro7 S9s,13 5DCS6"

) "istributed Control System is an elaborate, monolithic network of microprocessors that controlled "arious aspects of a process system. ) distributed control system %D'!( refers to a control system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location %like the brain( but are distributed throughout the system with each component sub+system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring. 1>.16 !7131n,s-a @ri1; 0i12 ) D'! typically uses custom designed processors as controllers and uses both proprietary interconnections and 'ommunications protocol for communication. Input / output modules form component parts of the D'!. The processor recei"es information from input modules and sends information to output modules. The input modules recei"e information from input instruments in the process %a.k.a. field( and transmit instructions to the output instruments in the field. 'omputer buses or electrical buses connect the processor and modules through multiple#er or demultiple#ers. uses also connect the distributed controllers with the central controller and finally to the Human+Machine Interface %HMI( or control consoles. $lements of a distributed control system may directly connect to physical e.uipment such as switches, pumps and "al"es or may work through an intermediate system such as a !')D) system. 1>.26 A887i/a,ion" DCS is a "ery broad term used in a "ariety of industries, to monitor and control distributed e.uipment.

$lectrical power grids and electrical generation plants $n"ironmental control systems

Traffic signals >ater management systems @il refining plants 'hemical plants -harmaceutical manufacturing !ensor networks Dry cargo and bulk oil carrier ships

They are comple# and e#pensi"e, and typically used proprietary hardware and software including control languages, so only the company that built them could ser"ice and support them. )nd once the system in place, it is difficult to adapt as your process re.uirements changed o"er time. B.,I they are capable of handling the largest and most comple# processing systems, making them a maDor step forward for continuous processing industries like Mining / !melting, -ower / $nergy, @il / Eas, >ater / >astewater, and -ulp / -aper.

1&. H9@ri- S9s,13s"

In the last decade, both historic D'! and -L' companies ha"e mo"ed toward a space that both call Whybrid,W in which they attempt to offer the power and comple#ity of D'!s and the fle#ibility, openness and low cost of -L' systems. D'! companies ha"e done this by reducing the footprint of their systems while -L' companies ha"e begun linking their components together to create more complete systems. ut though many were commercially successful, these Whybrid systemsW ha"e ne"er fully deli"ered on the original hybrid promise. Cor one thing, the D'! hybrids ha"e been unable to tailor their systems to become modular enough to work with both @$Ms / $nd ,sers and scalable, fle#ible enough to handle applications that range from small to large. In addition, the speeds of high speed se.uential or discrete processes V sometimes measured in the tens of milliseconds V are typically too fast for D'! hybrids to accommodate making applications like packaging or metal stamping or simple motor control difficult if not impossible to control. !o a hybrid plant with batch, continuous and discrete en"ironments or a large continuous processing plant with high speed se.uential control needs as well still had to ac.uire a second process system for their discrete areas, with all the e#tra cost, integration problems, increased training and maintenance that entailed.

Con/7.sion
$"ery aspect of industryVfrom power generation to automobile painting to food packagingVuses programmable controllers to e#pand and enhance production. Today, the two technologies share kingdoms as the functional lines between them continue to blur. >e now use each where the other used to rule. Howe"er, -L's still dominate high+speed machine control, and D'!s hold in comple# continuous processes. The 01 days training stint at HZL pro"ed to be a fruitful and learning e#perience as it pro"ided an opportunity for me to work in a rapidly de"eloping organi2ation stri"ing for e#cellence in its operations and ser"ices. The -roDect team, with whom I worked in my time spent here, not only cleared my basics knowledge but also e#plained the systematic and efficient manner in which they carry out their day to day operations for achie"ing customer satisfaction. The hierarchy at HZL insures that there is accountability and transparency in the system and the proDects undertaken are completed on or before time.

Bi@7io4ra8h9

Day to day notes The -L' theory book H L.). rayan, :.). rayan -rogrammable logic controllers H Hugh *ack -rogrammable logic controllers H >. olton Internet file linksA 3. httpAGG -rogrammable Logic 'ontrollers %-L's( !pecifications.htm 9. httpAGG -rogrammable logic controller + >ikipedia, the free encyclopedia.htm 0. httpAGG D'! "s -L'.htm ;. httpAGG Distributed control system + >ikipedia, the free encyclopedia.htm etc.