Jai Lal Meena

COLLEGE OF TECHNOLOGY AND ENGINEERING
Maharana Pratap University of Agriculture and Engineering UDAIPUR (RAJASTHAN)-313001, INDIA
A REPORT ON TRAINING Taken at PYROTECH ELECTRONICS PVT. Ltd., UDAIPUR
On
GENERATOR CONTROL PANELS & PLC PANELS

Submitted in partial fulfillment for the award of degree of Bachelor of Engineering (2010-11)
Jaimeena25@gmail.com
Submitted to: Dr. Navneet Agarwal Training Incharge.
Submitted by: Jailal meena 3 rd Yr. (ECE)
ACKNOWLEDGEMENT
I would like to express my sincere gratitude to Pyrotech Electronics Pvt. Ltd., Unit-2, Udaipur for giving me an opportunity to undergo my Industrial Training for four weeks for providing me knowledge of Purge Panels. I would also like to thank technical experts, engineers and executives for explaining practical aspects of the theoretical knowledge. My greatest debt in creating this project goes to the Assistant Manager, HRD Ms. Surabhi Soni (Project Incharge) who has given me the basic concepts of Purge Panels. Thank you Ms. for encouraging me every step of the way. I owe a personal thanks to Mr. P.C.Talesara(Director) who extended a full support and cooperation during my training period. Here I obtained practical knowledge. For this travel of knowledge & training, I am grateful & thankful to Mr. Sunil Joshi (HOD, Electronics & Communication Department, C.T.A.E. Udaipur) & Dr. Navneet Agarwal (Training Incharge) for initiating my interest in training.
Last but not the least I m indebted to my parents and friends for their constant encouragement and help in my endeavour. Needless to say, without all the above help and suggestions my training would not have been a success.
Jailal meena 3rd Yr ECE
PREFACE
With the ongoing revolution in electronic and communication where innovations are taking at the blink of eye, it is impossible to keep the pace with the emerging trends. Industrial approach to problem solving based on a broad understanding of process and mode of operation of organization. During this period, the student gets the real experience for working in the actual Industry environment. Most of the theoretical knowledge that has been gained during the course of their studies is put to test here. Apart from this student gets an opportunity to learn the latest technology, which is immensely helps in them in building their career. I had the opportunity to have a real experience on many ventures, which increased my sphere of knowledge to great extent. I got a chance to learn many new technologies and was also interfaced to many instruments.
CONTENTS
Profile of the company Introduction Pyrotech group Manufacturing facility Products Clients Company visit PLC Panels Introduction History Development Programming PLC Hardware Configuration Of Typical PLC Working Of PLC Advantages Of PLC Application Of PLC system PLC v/s Computer PLC Disadvantages Conclusion Generator Control Panel
General Description Controlling Our Machines Working
Bibliography
PROFILE OF THE COMPANY

Introduction
Pyrotech, Unit-2 provides complete solution for electronic process control instruments to the industries. Presently it is manufacturing about 200 different types of process control instruments. It has a strong R & D team, comprising of more than 50 engineers. It is a leading manufacturer of Electronic Process Control Instruments. Its product range includes Signal Converters, Transmitters, Electrical Transducers, Indicators, Flow Totalizer, Power Factor Correction Relays, Timers, Counters, Alarm Annunciator, Temperature Scanners, Speed Measuring Systems, TempMax Transmitters, Closed Circuit Television Systems and Special Instruments like Surge Arresters, Test Benches, Selector Switches, Rpm Generators & pH
Measuring Systems etc. It is a distributor of L&T AC/DC drives, Siemens field instruments,CCTV, Wireless Modems, Ultrasonic/Radar Level Transmitter. It also undertakes PLC automation jobs for the process control industries.
Pyrotech Group
Pyrotech Group (Control & Instrumentation Electronic & Sensor Equipment)
Pyrotech Electronic Pvt. Ltd. Unit II ISO 9001:2008 ISO 14001:2004 ISO 18001:2007 OHSAS (Control & Instrumentati on)
Pyrotech Electronic Pvt. Ltd. Unit I ISO 9001:2000 (Electricals & Electronics)
Tempsens Instrument ISO 9001:2000 (Temprature Sensors)
Pyrotech Marketin g& Project Pvt. Ltd. (Marketin g)
Pyrotech Workspa ce Solution Pvt. Ltd. ISO 9001:200 0
Industrial Automation
Annuniciator Thermocouple Services, Bar Resistance Marketing Graphindicat Thermometers(RTD' PLC or Tranducer s) Projects Scanner
Control Room & Control Desk Interior
Manufacturing Facility
CNC hydraulic press punch, system controller -siemens 840D model name -aquila 1250, linear turret trumph type, multistation (11 station). This multitool turret incorporates advantages such as: (A) Reduced throughput cycle. (B) High Accuracy (C) Better Machinability (D) Versality in punching hole.
Converized powder coating plant with 2 booth ro ro & 4 paint guns back to back oven size 11mtr, 25 mtr length with omega loop conveyor, overall conveyor length 120 mtr. this plant facilitate features like (a)Reduced handling hassles (b)Uniform thickness through the sheet (C)Considerable reduction in time cycle
Well set material management department that looks after planning & procurement, vendor development & support, quality improvement, cost reduction, import substitution etc.
Sheet surface treatment shop 7 tank system (7000 liter capacity) 7 tank system (2500 liter capacity) Hot seven tank process generates phosphated & chromatised sheet having good resistance to oxidation and errosion. Being an automated conveyorised plant the cycle time of each dip is precisely fixed.
Specialized designed programs and CAD software generate faster design output. Our designers help you visualize your product in advance.
The product development process includes stringent internal testing. Each enclosure is subjected to harsh environmental conditions. Extensive & rigorous testing for paint, mechanical, electrical, calibration, measurement & functional testing of panels is undertaken to ensure they meet our standards & customer's requirements.
Fabrication shop is equipped with power press, arc / mig / tig / spot welding machines, pneumatic riveting and grinding machines to ensure reliable process.
Stud welding machine bms-10n/2 model no.: p01050a00329-04 this new machine renders better finish to the sheet due to removal of depression & burrs.
Wiring for plc - swing arms, mosaics, connectors etc. with suitable ferruling is done. termination from 0.5 mm2 to 60mm2 is possible.
Products
PANELS & CONTROLS DESKS
MOSAIC PANEL & DESK MIMIC PANEL CONTROL PANEL PLC PANEL MARSHALLING PANEL NETWORKING PANEL 19" TRANSDUCER PANEL 19" RACK PANEL MCC PANEL PURGE & EXPLOSION PROOF PANEL JUNCTION BOX METERING BOX LIE/LIR SHELTER PANEL HT PANEL NG & LAVT CUBICLE TEST BENCH COMPUTER CONSOLES
SYSTEM INTEGRATIONS DISTRIBUTORSHIP
SYNELEC - LARGE VIDEO SCREEN

SUPTEAM - MOSAIC TILE SYSTEM
WEIGEL - PANEL METERS AND ACCESSORIES
WORKSPACE SOLUTION
INDUSTRIAL FURNITURE OFFICE FURNITURE
Clients

ASEA BROWN BOVARILTD., BANGLORE, NEW DELGHI, BARODA JINDAL POWER, RAIGARH ALSTOM TRANSPORT J.K. CEMENT WORKS, NIMBAHERA AREVA,NOIDA J.K. INDUSTRIES LTD. KIRLOSKAR BROTHERS LTD. KRIBHCO AMBUJA CEMENT LARSEN & TOUBRO LIMITED, MUMBAI, CHENNAI, BARODA BHABHA ATOMIC RESEARCH CENTRE MCNALLY BHARAT ENGINEERING CO. LTD. BENTLY NEVADA METSO AUTOMATION (NELES AUTOMATION) BHARAT ELECTRONICS LTD. MTL SYSTEMS LTD. CHENNAI BHARAT HEAVY ELECTRICALS LIMITED, BANGLORE, BHOPAL, HARDWAR, HYDRABAD NATIONAL FERTILISERS LTD., PANIPAT BINANI CEMENT LTD. NELCO LIMITED BIRLA CORPORATIONLTD., CHITTOGARH NUCLEAR POWER CORPORATION BPCL NATIONAL THERMAL POWER CORPORATION
BSES LIMITED PESTICIDES INDIA LTD., UDAIPUR CROMPTON GREAVES PYRAMID CONTROL SYSTEMS (P) LTD. DANIEL MEASUREMENT & CONTROL (I) PVT. LTD. RELIENCE INDUSTRIES LTD. DRDL, HYDERABAD ROCKWELL AUTOMATION INDIA LTD. ELECTRONICS CORPORATION INDIA LTD. SECURE METERS LIMITED ENGINEERS INDIA LTD. SCHNIDER ELECTRIC INDIA LTD. EMERSON PROCESS SHREE CEMENT LTD. FLS AUTOMATION INDIA LTD. SIEMENS LTD. KOLKATTA, NEW DELHI , MUMBAI, GURGAON GE FANUC SYSTEMS LTD., BANGLORE SUZLON ENERGY LTD GRASIM INDUSTRIES LTD. TATA HONEWELL LIMITED., PUNE GTRE, BANGLORE TATA LTD, HONEYWELL,PUNE TECHNIP ITELY S.P.A. INSTRUMENTATION LTD., KOTA THE ASSOCIATED CEMENT COMPANIES LTD INDIAN FARMERS & FERTILISER COOPORATIVE THERMAX, PUNE INDIAN OIL TANKING LTD. TRF LTD INDURE LTD. TRIVENI ENGG. & INDUSTRIES LTD ION EXCHANGE (INDIA) LTD. WESTINGHOUSE, DELHI JINDAL STEELS, RAIGARH YOKOGAWA BLUE STAR, BANGLORE
COMPANY VISIT
A company involves various departments for the completion of suitable tasks like designing, manufacturing, marketing etc. Theae departments involve various processes to furnish the task. Pyrotech is also working with the same concept for the manufacturing of the panels. A brief description of PEPL #2 is given below.
Maketing:
This department of PEPL keeps an eye over the marketing areas, consumers and competitors to stay tuned.
Design:
The design department of PEPL is well equipped with latest designing softwares including AUTOCAD. Highly learned and qualified team of draftmen and Engineers work to come up with the perfect panel design.
Purchase:
A separate department looks after the requirement and procurement of the material and equipment.
Production:
PEPL has the motto Its not the less price that sells, it is the quality. PEPL is equipped with the latest technology in the production of control panel.
Storage:
Raw material is purchased according to the need of company and after purchasing the raw material is sent at Unloaded room where it is examined as weight, height etc. Main raw material is Sheets. These sheets are mainly of the following types:
Stainless steel (SS) Aluminium CRCA (Cold Rolled Cold Annealed) HRCA (Hot Rolled Cold Annealed)
PROGRAMMABLE LOGIC CONTROLLER
INTRODUCTION
A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or lighting fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements,
extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or non-volatile memory. A PLC is an example 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. Programmable logic controllers (PLCs) are members of the computer family capable of storing instructions to control functions such as sequencing, timing, and counting, which control a machine or a process. The PLC is composed of two basic sections, the Central Processing Unit (CPU) and the Input/Output (I/O) interface system. The PLC measures input signals coming from a machine and through the internal program provides output or control back to the machine. Ladder logic is the programming language used to represent electrical sequences of operation. In hardwired circuits the electrical wiring is connected from one device to another according to logic of operation. In a PLC the devices are connected to the input interface, the outputs are connected to the output interface and the actual wiring of the components is done electronically inside
the PLC using ladder logic. This is known as soft wired. PLC is a device that is capable of being programmed to perform a controlling function. logic control system. The PLC was first conceived by group of engineers from hydramatic division of GM in 1968.This was designed to provide flexibility in control based on programming and executing logic instruction.
HISTORY
The PLC was invented in response to the needs of the American automotive manufacturing industry. Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles was accomplished using hundreds or thousands of relays, cam timers, and drum sequencers and dedicated closed-loop controllers. The process for updating such facilities for the yearly model change-over was very time consuming and expensive, as electricians needed to individually rewire each and every relay. In the late 1960's PLCs were first introduced. The primary reason for designing such a device was eliminating the large cost involved in replacing the complicated relay based machine control systems. Bedford Associates (Bedford, MA) proposed something called a Modular Digital Controller (MODICON) to a major US car manufacturer. One of the people who worked on that project was Dick Morley, who is considered to be the "father" of the PLC. Other companies at the time proposed computer based schemes, one of which was based upon the PDP-8. The MODICON 084 brought the world's first PLC into commercial production.
DEVELOPMENT
Early PLCs were designed to replace relay logic systems. These PLCs were programmed in "ladder logic", which strongly resembles a schematic diagram of relay logic. This program notation was chosen to reduce training demands for the existing technicians. Other early PLCs used a form of instruction list programming, based on a stack-based logic solver. Modern PLCs can be programmed in a variety of ways, from ladder logic to more traditional programming languages such as BASIC and C. Another method is State Logic, a very high-level programming language designed to program PLCs based on state transition diagrams. Many early PLCs did not have accompanying programming terminals that were capable of graphical representation of the logic, and so the logic was instead represented as a series of logic expressions in some version of Boolean format, similar to Boolean algebra. As programming terminals evolved, it became more common for ladder logic to be used, for the aforementioned reasons. Newer formats such as State Logic and Function Block (which is similar to the way logic is depicted when using digital integrated logic circuits) exist, but they are still not as popular as ladder logic. A primary reason for this is that PLCs solve the logic in a predictable and repeating sequence, and ladder logic allows the programmer (the person writing the logic) to see any issues with the timing of the logic sequence more easily than would be possible in other formats.
PROGRAMMING
Early PLCs, up to the mid-1980s, were programmed using proprietary programming panels or special-purpose programming terminals, which often had dedicated function keys representing the various logical elements of PLC programs. Programs were stored on cassette tape cartridges. Facilities for printing and documentation were very minimal due to lack of memory capacity. The very oldest PLCs used non-volatile magnetic core memory. More recently, PLCs are usually programmed using special application software written for use on desktop computers, and connecting between the desktop computer and the PLC such as via Ethernet or RS-232 cabling. Such software allows entry and editing of the ladder-style logic, and then may provide additional functionality to assist debugging and troubleshooting the software (for example, by highlighting portions of the logic to show current status during operation or via simulation). Finally, the software may allow uploading and downloading of the program between the computer and the PLC, for backup and restoration purposes. Alternately, specific devices known as programming boards are used to hard wire the logic into the controller by the use of a removable chip, such as an EEPROM, where the program is transferred to the programming board from the workstation via serial or other bus logic.
PLC HARDWARE
A programmable logic controller consists of the following components: Central Processing Unit (CPU). Memory. Input modules. Output modules and Power supply. A PLC diagram is shown in Figure.
Processor
Programming CH 1 Supply Power Processor Software Mmmmmm CH 2 mmememo mory CH 3
CHn
CH n
I/P O/P Connection Connection from to Industrial Industrial Equipment Equipment

Configuration of Typical PLC CPU

Like other computerized devices, there is a Central Processing Unit (CPU) in a PLC. The CPU, which is the brain of a PLC, does the following operations: Updating inputs and outputs. This function allows a PLC to read the status of its input terminals and energize or deenergize its output terminals. Performing logic and arithmetic operations. A CPU conducts all the mathematic and logic operations involved in a PLC. Communicating with memory. The PLCs programs and data are stored in memory. When a PLC is operating, its CPU may read or change the contents of memory locations. Scanning application programs. An application program, which is called a
ladder logic program, is a set of instructions written by a PLC programmer. The scanning function allows the PLC to execute the application program as specified by the programmer. Communicating with a programming terminal. The CPU transfers program and data between itself and the programming terminal. A PLCs CPU is controlled by operating system software. The operating system software is a group of supervisory programs that are loaded and stored permanently in the PLCs memory by the PLC manufacturer.
MEMORY
Memory is the component that stores information, programs, and data in a PLC. The process of putting new information into a memory location is called writing. The process of retrieving information from a memory location is called reading. The common types of memory used in PLCs are Read Only Memory (ROM) and Random Access Memory (RAM). A ROM location can be read, but not written. ROM is used to store programs and data that should not be altered. For example, the PLCs operating programs are stored in ROM. A RAM location can be read or written. This means the information stored in a
RAM location can be retrieved and/or altered. Ladder logic programs are stored in RAM. When a new ladder logic program is loaded into a PLCs memory, the old program that was stored in the same locations is over-written and essentially erased. The memory capacities of PLCs vary. Memory capacities are often expressed in terms of kilo-bytes (K). One byte is a group of 8 bits. One bit is a memory location that may store one binary number that has the value of either 1 or 0. (Binary numbers are addressed in Module 2). 1K memory means that there are 1024 bytes of RAM. 16K memory means there are 16 x 1024 =16384 bytes of RAM.
INPUT AND OUTPUT MODULES
A PLC is a control device. It takes information from inputs and makes decisions to energize or de-energize outputs. The decisions are made based on the statuses of inputs and outputs and the ladder logic program that is being executed. The input devices used with a PLC include pushbuttons, limit switches, relay contacts, photo sensors, proximity switches, temperature sensors, and the like. These input devices can be AC (alternating current) or DC (direct current). The input voltages can be high or low. The input signals can be digital or analog. Differing inputs require different input modules. An input module provides an interface between input devices and a PLCs CPU, which uses only a low DC voltage. The input modules function is to convert the input signals to DC voltages that are acceptable to the CPU. Standard discrete input modules
include 24 V AC, 48 V AC, 120 V AC, 220 V AC, 24 V DC, 48 V DC, 120 V DC, 220 V DC, and transistor-transistor logic (TTL) level. The devices controlled by a PLC include relays, alarms, solenoids, fans, lights, and motor starters. These devices may require different levels of AC or DC voltages. Since the signals processed in a PLC are low DC voltages, it is the function of the output module to convert PLC control signals to the voltages required by the controlled circuits or devices. Standard discrete output modules include 24 V AC, 48 V AC, 120 V AC, 220 V AC, 24 V DC, 48 V DC, 120 V DC, 220 V DC, and TTL level.
POWER SUPPLY
PLCs are powered by standard commercial AC power lines. However, many PLC components, such as the CPU and memory, utilize 5 volts or another level of DC power. The PLC power supply converts AC power into DC power to support those components of the PLC.
PROGRAMMING TERMINAL
A PLC requires a programming terminal and programming software for operation. The programming terminal can be a dedicated terminal or a generic
computer purchased anywhere. The programming terminal is used for programming the PLC and monitoring the PLCs operation. It may also download a ladder logic program (the sending of a program from the programming terminal to the PLC) or upload a ladder logic program (the sending of a program from the PLC to the programming terminal). The terminal uses programming software for programming and talking to a PLC.
WORKING OF PLC
Bringing input signal status to the internal memory of CPU The field signals are connected to the I/P module. At the output of I/P module the field status converted into the voltage level required by the CPU is always available. At the beginning of each cycle the CPU brings in all the field I/P signals from I/P module & stores into its internal memory called as PII, meaning process image input. The programmable controller operates cyclically meaning when complete program has been scanned; it starts again at the beginning of the program.
I/O BUS
A PLC works by continually scanning a program. We can think of this scan cycle as consisting of 3 important steps. Step 1-Check Input Status-First the PLC takes a look at each input to determine if it is on or off. In other words, is the sensor connected to the first input on How about the second input How about the third... It records this data into its memory to be used during the next step. Step 2-Execute Program-Next the PLC executes your program one instruction at a time. Maybe your program said that if the first input was on then it should turn on the first output. Since it already knows which inputs are on/off from the previous step it will be able to decide whether the first output should be turned on based on the state of the first input. It will store the execution results for use later during the next step. Step 3-Update Output Status-Finally the PLC updates the status of the outputs. It updates the outputs based on which inputs were on during the first step and the results of executing your program during the second step. Based on the example in step 2 it would now turn on the first output because the first input was on and your program said to turn on the first output when this condition is true. Process Control and Automation Process Control The process of recognizing the state of the process at all times, analyze the information according to the set rules and guidelines and accordingly actuate the control elements is referred to as process control.
FUNCTIONALITY
The functionality of the PLC has evolved over the years to include sequential relay control, motion control, process control, distributed control systems and networking. The data handling, storage, processing power and communication capabilities of some modern PLCs are approximately equivalent to desktop computers. PLC-like programming combined with remote I/O hardware, allow a general-purpose desktop computer to overlap some PLCs in certain applications. Regarding the practicality of these desktop computer based logic controllers, it is important to note that they have not been generally accepted in heavy industry because the desktop computers run on less stable operating systems than do PLCs, and because the desktop computer hardware is typically not designed to the same levels of tolerance to temperature, humidity, vibration, and longevity as the processors used in PLCs. In addition to the hardware limitations of desktop based logic, operating systems such as Windows do not lend themselves to deterministic logic execution, with the result that the logic may not always respond to changes in logic state or input status with the extreme consistency in timing as is expected from PLCs. Still, such desktop logic applications find use in less critical situations, such as laboratory automation and use in small facilities where the application is less demanding and critical, because they are generally much less expensive than PLCs. In more recent years, small products called PLRs (programmable logic relays), and also by similar names, have become more common and accepted. These are very much like PLCs, and are used in light industry where only a few points of
I/O (i.e. a few signals coming in from the real world and a few going out) are involved, and low cost is desired. These small devices are typically made in a
common physical size and shape by several manufacturers, and branded by the makers of larger PLCs to fill out their low end product range. Popular names include PICO Controller, NANO PLC, and other names implying very small controllers. Most of these have between 8 and 12 digital inputs, 4 and 8 digital outputs, and up to 2 analog inputs. Size is usually about 4" wide, 3" high, and 3" deep. Most such devices include a tiny postage stamp sized LCD screen for viewing simplified ladder logic (only a very small portion of the program being visible at a given time) and status of I/O points, and typically these screens are accompanied by a 4-way rocker push-button plus four more separate pushbuttons, similar to the key buttons on a VCR remote control, and used to navigate and edit the logic. Most have a small plug for connecting via RS-232 to a personal computer so that programmers can use simple Windows applications for programming instead of being forced to use the tiny LCD and push-button set for this purpose. Unlike regular PLCs that are usually modular and greatly expandable, the PLRs are usually not modular or expandable, but their price can be two orders of magnitude less than a PLC and they still offer robust design and deterministic execution of the logic.
COMMUNICATION
PLCs have built in communications ports, usually 9-pin RS-232, but optionally EIA-485 or Ethernet. Modbus, BACnet or DF1 is usually included as one of the communications protocols. Other options include various fieldbuses such as
DeviceNet or Profibus. Other communications protocols that may be used are listed in the List of automation protocols. Most modern PLCs can communicate over a network to some other system, such as a computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser. PLCs used in larger I/O systems may have peer-to-peer (P2P) communication between processors. This allows separate parts of a complex process to have individual control while allowing the subsystems to co-ordinate over the communication link. These communication links are also often used for HMI devices such as keypads or PC-type workstations.
ADVANTAGES OF PLC
Reduced space. Energy saving. Ease of maintenance. Economical. Greater life and reliability. Tremendous flexibility. Shorter project time. Easier storage, archiving and documentation. PLCs are armored for severe conditions (such as dust, moisture, heat, cold) and have the facility for extensive input/output (I/O) arrangements. PLCs read limit switches, analog process variables (such as temperature and pressure), and the positions of complex positioning systems. PLCs are used in many "real world" applications. If there is industry present,
chances are good that there is a plc present. If you are involved in machining, packaging, material handling, automated assembly or countless other industries you are probably already using them. If you are not, you are wasting money and time. Almost any application that needs some type of electrical control has a need for a plc.
APPLICATIONS OF PLC SYSTEM
In industry, there are many production tasks, which are of highly repetitive nature. Although repetitive & monotonous, each stage needs careful attention of operator to ensure good quality of final product. Many times, a close supervision of the processes cause high fatigue on operator resulting in loss of track of process control. Sometimes its hazardous also as in the case of potentially explosive chemical processes. Under all such conditions we can use PLCs effectively in totally eliminating the possibilities of human error. Some capabilities of PLCs are as follows:
1. Logic control 2. PID control 3. Coordination & automation 4. Operator control 5. Signaling and listing etc. In short, wherever sequential logic control & automation is desired the PLCs are the best suited to meet the task. It includes simple interlocking functions to complicated analog signal processing to PID control action in closed loop control etc. Few examples of industries where PLCs are used for control & automation purpose are listed below: 1. Tyre industry. 2. Blender reclaimer. 3. Bulk material handling system at ports. 4. Ship unloader. 5. Wagon loaders. 6. Steel plants. 7. Blast furnace charging. 8. Brick-moulding press in refectories. 9. Galvanizing plant. 10. Dairy automation. 11. Pulp factory. 12. Printing industry etc. Today the PLCs are used for control and automation job in a single machine and it increases up to full automation of manufacturing or testing process in a
factory. In robotics: PLC is used for two tasks in robotics: 1) As the controller or unprogrammble part of robot. 2) As an overall system controller. In flexible manufacturing system: The logical development from linking machines in this manner is to group programmable machines into flexible manufacturing cells, each capable of machining a variety of products under fully automatic control. In factory automation: The Austin-rover assembling plant. The plant produces multi style car body from individual body panels .
The process consists of following activities: 1. Make up of sub assemblies from panels. Eg: doors, under frames 2. Tag sub assemblies together. 3. Pass tagged bodies to a main jig for automatic alignment & framing. 4. Conduct material transfer in which sub assemblies are selected, transported & distributed to workstation by conveyor system 5. Maintain quality control by automatic monitoring & manual inspection of each process. The PLC tracks each component as it moves through the production area, communicating this information to each appropriate robot as necessary. Data
send between PLC & robot includes handshaking signals to indicate robot busy parked, action complete etc. Data in binary coded decimal form is used to send component information & weld sequences from the PLC to root, which must acknowledge receipt of the correct data before the PLC will allow it to commence operation.
PLC PANEL
PLC VS COMPUTER
PLC Designed for extreme industrial environments. Can operation in high temperature and humidity. Er
High immunity to noise. Integrated command interpreter (proprietary). No secondary memory available (in the PLC). Optimized for Single task.Optimized Task Computer Designed mainly for data processing and calculation. Optimized for speed. Cant operate in extreme environments. Can be programmed in different languages. Lost of secondary memory available. Multitasking capability.
PLC DISADVANTAGES
In contrast to microcontroller systems that have what is called an open architecture, most PLCs manufacturers offer only closed architectures for their products. PLC devices are proprietary, which means that parts and software from one manufacturer can t easily be used in combination with parts of another manufacturer, which limits the design and cost options.
CONCLUSION
PLC is a device that is capable of being programmed to perform a controlling function. The PLC was designed to provide flexibility in control based programming and executing logic instruction. PLC allowed for shorter installation time and faster commissioning through programming rather than wiring. The PLC have in recent years experienced an unprecedented growth as universal element in industrial automation .It can be effectively used in applications ranging from simple control like replacing a small number of relays to complex automation problems. Today the PLCs are used for control & automation job in a single machine & it increases up to full automation of manufacturing / testing process in a factory
GENERATOR CONTROL PANEL

80-1600 Amps 208-600Vac, 50/60Hz rated MEC 20 Microprocessor-based Engine/Generator Controller Digital AC/DC Instrumentation Certifi ed to UL#508, CSA C22.2#14 Industrial Control Equipment Standards In compliance with NFPA Level 1 or 2 Unit or Wall Mount Oil Pressure and Water Temperature Sensors included Optional expansion output module for fault output contacts Standard remote communication feature Optional remote annunciator
GENERAL DESCRIPTION
The UCS 200 series auto start generator control panel is the most cost effective full featured control system available. Over 30 years of design and manufacturing experience have led to the creation of the UCS 200 panel family. One control panel can now meet your generator set control requirements throughout the world. The control center of the UCS 200 system is the MEC 20 Microprocessor based Engine Generator Controller. The MEC 20 gives the customer a compact, user friendly, eld programmable control package. The MEC 20s complement of standard features has previously only been available with costly and complicated PLC based control systems or as an expensive option from engine/generator packagers. The UCS 200 family of control panels is available in three basic models: Version C (Control only version, no breaker, no current transformers)
customized factory programming and options available Version S (Control only version, no breaker, no current transformers)
available from stock, programming by customer Version KD Knockdown (unassembled)
All models are designed to meet or exceed NFPA 110 Level 1, CSA C282 and IEC generator set requirements without adding optional features. Optional features are available in the UCS 200 C model to meet your custom application requirements. The UCS 200 S version is available from stock with standard con guration.
Controlling Our Machines
Any complex piece of
machinery
requires a user interface to enable the user to monitor its operations, check for efficient functioning, and intervene when required. Machines overheat, slow down, speed up or generally vary in their performance based on numerous factors such as fatigue, weather conditions, and the wear and tear of components and parts. In electrical machines, like generators, these varying changes constitute an electrical signal. These signals can be intelligently processed to control the performance of the machine. A lot of machines in urban environments (such as signal lights and automatic doors) are completely self-managed due to such controllers. They have sensors that can detect changes in physical attributes like heat and speed and generate signals accordingly. Modern generators also have similar sensors to detect changes in all kinds of various parameters. These can be used to control the generator through a control panel.
Working
The control panel is becoming an increasingly complex piece of electronics with a microprocessor that can manipulate input from sensors to help give feedback to the machine to manage itself. One such feedback could be the temperature, indicating overheating, other examples would be over/under speed and low/high oil pressure. Typically, a heat sensor inside the generator would sense the build up of heat in the generator body and pass this to the microprocessor in the control panel. The microprocessor will then take effective measures to regulate the performance of the machine including shutdowns if, for example, the oil pressure is too low or the coolant temperature is too high, leading to buildup of heat. In industrial situations, this functionality of control panels is becoming increasingly critical. The microprocessor or microcontroller is embedded in the circuitry inside the control panel and is programmed to take in the sensor input and react to that with the programmed control rules.
Control panels can be combined with an Automatic Transfer Switch (ATS) to maintain the continuity of electrical power. The ATS detects an outage of power
when your local grid fails. It signals the control panel to start the generator. Depending on the type of generator being used, the control panel may activate glow plugs (for diesel) for an adjustable length of time. It will then start the generator using an automatic starter, similar to the one you engage when you turn the keys in the ignition of your car in the morning. As soon as the engine of the generator reaches an optimum speed, the starter is disengaged. The ATS then switches to the generator power, and you can go back to business as usual, without having to frantically scramble to figure out what caused power loss. This aspect of a control panel makes it extremely useful in homes during bad weather and in industrial situations for ensuring mission-critical continuity
Bibliography Net links:

1. 2. 3. 4.
http://www.tanswa.net/purge-panels.html http://www.pyrotechindia.com/purge_pnl.asp http://www.exloc.com/purging_mm.html http://www.ncsu.edu/ehs/www99/right/handsMan/compgas/purgereq.ht ml

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COLLEGE OF TECHNOLOGY AND ENGINEERING

Maharana Pratap University of Agriculture and Engineering UDAIPUR (RAJASTHAN)-313001, INDIA

A REPORT ON TRAINING Taken at PYROTECH ELECTRONICS PVT. Ltd., UDAIPUR

GENERATOR CONTROL PANELS & PLC PANELS

Submitted to: Dr. Navneet Agarwal Training Incharge.

Submitted by: Jailal meena 3 rd Yr. (ECE)

Jailal meena 3rd Yr ECE

General Description Controlling Our Machines Working

PROFILE OF THE COMPANY

Pyrotech Group (Control & Instrumentation Electronic & Sensor Equipment)

Tempsens Instrument ISO 9001:2000 (Temprature Sensors)

Pyrotech Marketin g& Project Pvt. Ltd. (Marketin g)

Pyrotech Workspa ce Solution Pvt. Ltd. ISO 9001:200 0

Control Room & Control Desk Interior

PANELS & CONTROLS DESKS

SYSTEM INTEGRATIONS DISTRIBUTORSHIP

SYNELEC - LARGE VIDEO SCREEN

WEIGEL - PANEL METERS AND ACCESSORIES

INDUSTRIAL FURNITURE OFFICE FURNITURE

PROGRAMMABLE LOGIC CONTROLLER

Programming CH 1 Supply Power Processor Software Mmmmmm CH 2 mmememo mory CH 3

I/P O/P Connection Connection from to Industrial Industrial Equipment Equipment

Configuration of Typical PLC CPU

INPUT AND OUTPUT MODULES

APPLICATIONS OF PLC SYSTEM

GENERATOR CONTROL PANEL

available from stock, programming by customer Version KD Knockdown (unassembled)

Controlling Our Machines

Any complex piece of

Bibliography Net links:

http://www.tanswa.net/purge-panels.html http://www.pyrotechindia.com/purge_pnl.asp http://www.exloc.com/purging_mm.html http://www.ncsu.edu/ehs/www99/right/handsMan/compgas/purgereq.ht ml

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