An AUTOMATION Perspective

of
ESSAR BULK TERMINAL
SALAYA LIMITED
 SL SUL
SUL
JH-1
JH-2

JH-5

JH-6
JH-4 JH-3
JH-7
SILO

JH-16
JH09 JH12
JH-8
JH10 JH13

JH11 JH14

JH15
JH18
EPGL (SILO)
(BUNKER) JNT
JH17
1

VPCL JNT
1
JH19
 DG SET DG SET
ER-2 Near DG SET SS-1A SS-1 160 KVA
JH-17 Near JH-6 Near JH-
100 KVA
2
TRANSFORMER MOTORS TRANSFORMER MOTORS
TRANSFORMER MOTORS
1)DTR 1)6 x 200 KW(VFD) 1)DTR 1)1 x 900
for YC-1,2,3(2 each) 1)DTR 1)2 x 200 KW(VFD)
2 x 25 MVA 2 x 7.5 MVA(33/11), KW(VFD)
in JH-12,13,14 2 x 25 MVA for PCC-6,PCC-5(1
(33/11), 2 x 0.5 MVA(11/.433) for CPCC-
respectively. (33/11), each) in JH-1,2
2 x 1.5 2)CTR 2 in JH-6
2)2 x 200 KW(DOL) 2 x 1.5 respectively.
MVA(11/.433), 2 x 2.5 MVA 2)1 x 700
for CC-6A,6B(1 MVA(11/.433) 2)2 x 500 KW(VFD)
2 x 1.2 MVA (11/.72/.72) KW(VFD)
each) in JH-17. 2)CTR for CC-1,2(1 each) in
(11/.72) 4) LIGHTING TR for CC-4
3) 2 x 5.5 KW FG 2 x 2.5 MVA JH-2,3 respectively.
2)CTR 1 x 100 KVA in JH-6
in JH-12 (11/.72/.72) 3) 1 x 150 KW(VFD)
2 x 2.0 MVA (.415/.380)
4)2 x 5.5 KW FG 3) LIGHTING TR for CC-2 in JH-3.
(11/.72/.72) ER-1B
in JH-13,14(1 each) 1 x 200 KVA
3) LIGHTING TR ER-1A
5)2 x 5.5 KW FG Near (.415/.380)
1 x 300 KVA Near JH-5
in JH-15 JH-6A
(.415/.380)
6)2 x 5.5 KW FG
in JH-17 TRANSFORMER MOTORS TRANSFORMER MOTORS
SS-2 Near
JH-8 1)DTR 1)2 x 900 1)DTR 1)1 x 900 DG SET
2 x 0.5 KW(VFD) 2 x 0.5 KW(VFD) ER-1
TRANSFORMER MOTORS MVA(11/.433) for CPCC-1 MVA(11/.433) for CPCC-2 30 KVA
Near JH-4
1)3 x 900 KW(VFD) for 2)CTR in JH-5 2)CTR in JH-6A
1)DTR CPCC-2 in JH-8 2 x 3.5 MVA 2)1 x 250 2 x 1.5 MVA
2 x 1.5 2)2 x 200 KW(DOL) for (11/.72/.72) KW(VFD) (11/.72/.72) MOTORS
TRANSFORMER
MVA(11/.433), CC-5A,5B(1 each) in 3) LIGHTING TR for PCC-3 3) LIGHTING
2 x 2.5 MVA JH-11. 1 x 100 KVA in JH-5. TR
(11/.72) 3) 1 x 200 KW(DOL) (.415/.380) 1 x 150 KVA 1)DTR 1)1 x 900
2)CTR for PCC-1 in JH-16 (.415/.380) 2 x 0.5 KW(VFD)
2 x 4.0 MVA 4)1 x 150 KW(DOL) MVA(11/.433) for CPCC-1
(11/.72/.72) for PCC-2 in JH-7 2)CTR in JH-4
3) LIGHTING TR 5)6 x 18.5 KW 2 x 2.0 MVA 2)1 x 400
1 x 350 KVA for RBF in JH-8 (11/.72/.72) KW(VFD)
(.415/.380) 6)6 x 5.5 KW FG 3) LIGHTING for CC-3 in
in JH-8(2),9(2),10(2) TR JH-4.
DG SET 1 x 100 KVA
7)1 x 150 KW(DOL)
400 KVA for EFC (.415/.380)
SS-1 ER-1A SS-2 ER-2 ER-3 ER-4

FCPU-1 FCPU-2 FCPU-3 FCPU-4 FCPU-5 FCPU-6

ER-1 ER-1A ER-1B

RIO-1 RIO-2A RIO-2B RIO-3A RIO-3B

 FCPU-4
CONTOL ROOM
FIBRE
HMI
10-100 OPTICS(FO)
(52’’ LCD
mbps CABLE
DISPLAY,OPERATING
L ETHERNET STATIONS) L
I I
U U

PM864A
CI854A
PM864A

CI867
CI854A
CI867
CI853

DO810

DO810
AO810
DI810
DI810

DI810

AI810
AI810
AI810
CI840
CI840
SCR-
1,2,3,4 PCMU,
EM,
BSMU,
FDAS, I/O CLUSTERS
ZSC,
UPS
RELAY CI840
CI840

DO810

DO810
AO810
DI810
DI810

DI810

AI810
AI810
AI810
MOD BUS TCP
MOD BUS RTU
PROFIBUS DP CABLE
 AC 800M CONTROLLER

 AC 800M is a modular, energy efficient and scalable industrial controller belonging

to ABB’s controller family. It is configured and programmed with Control
Builder M, a fully Windows 2000-integrated application.
 It is communicative too by supporting industry-standard field buses &
communication protocols such as RS-232C, Ethernet, Profibus®, Foundation Fieldbus®

and Hart®.
 The units mount on a DIN rail and interface directly with ABB’s S800 I/O system, but
thanks to the system´s communicative abilities it can manage many other I/O
systems as well, including all Profibus DP/ DP-V1-proficient systems.
 AC 800M Architecture
CPU S800L I/O
Optional up to 12
Communication modules

Compact
Flash slot

Redundant
Ethernet 2 RS-232 channels

Totally can up to 96 S800 I/O modules be connected as direct I/O to AC800M

Up to 12 I/O modules can directly be connected to the CPU via the electrical Modulebus
Up to 84 I/O modules can be connected via I/O clusters via the optical Modulebus
 AC 800M Architecture
CPU S800L I/O
Optional up to 12
Communication modules

Compact
Flash slot

Redundant
Ethernet 2 RS-232 channels

Totally can up to 96 S800 I/O modules be connected as direct I/O to AC800M

Up to 12 I/O modules can directly be connected to the CPU via the electrical Modulebus
Up to 84 I/O modules can be connected via I/O clusters via the optical Modulebus
 Flexible and scalable in size and performance
Up to 48
Control Network Controllers on
(Ethernet TCP/IP, Control Network
10Mbps)
Max 12 S800
Max 12 modules on
Communication Electrical
modules on CEX bus Modulebus
Optical
Remote S800 I/O via ModuleBus
PROFIBUS DP/V1
I/O Cluster Max 12 S800
Max 24 S800 modules per I/O
Cluster
modules per
remote I/O
station

< 1000m

Max 7 S800 I/O Clusters

Note: See AC 800M Controller Hardware User Manual for details about supported combinations
 AC 800M Open Architecture

PM8xx
CI858

CI857

CI856
CI855

CI854
CI853
PROFIBUS DP
DriveBus

S100 I/O

Network
Control
MB300
INSUM

RS232
RS232
AC 800M options for communication includes;

• Networks: Control Network, MB300, SattBus on TCP/IP

• Field buses: PROFIBUS DP
• Serial protocols: COMLI, Modbus RTU, Siemens 3964R, user defined
• Process device/instrument: INSUM switchgear, ABB Drives
• I/O systems: S100, S200, S800, S900
CI840
 BENEFITS OF PLC
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other
systems quickly and easily.
• Computational abilities allow more sophisticated
control.
• Trouble shooting aids make programming easier
and reduce downtime.
• Reliable components make these likely to operate
for years before failure.
 PLC HARDWARE
• Power Supply - This can be built into the PLC or be an external
unit. Common voltage levels required by the PLC (with and
without the power supply) are 24Vdc, 120Vac, 220Vac.
• CPU (Central Processing Unit) - This is a computer where
ladder logic is stored and processed.
• I/O ( Input/ Output) - A number of input/output terminals
must be provided so that the PLC can monitor the process and
initiate actions.
• Indicator lights - These indicate the status of the PLC including
power on, program running, and a fault. These are essential
when diagnosing problems.
 Outputs to actuators allow a PLC to cause something to happen in a process.
A short list of popular actuators is given below in order of relative popularity.

Solenoid Valves - logical outputs that can switch a hydraulic or

pneumatic flow.

Lights - logical outputs that can often be powered directly from PLC
output boards.

Motor Starters - motors often draw a large amount of current when

started, so they require motor starters, which are basically large relays.

Servo Motors - a continuous output from the PLC can command a

variable speed or position.

Outputs from PLCs are often relays, but they can also be solid state electronics
such as transistors for DC outputs or Triacs for AC outputs. Continuous
outputs require special output cards with digital to analog converters.
Inputs come from sensors that translate physical
phenomena into electrical signals.
Typical examples of sensors are listed below in
relative order of popularity.
Proximity Switches - use inductance, capacitance or
light to detect an object logically.
Switches - mechanical mechanisms will open or close
electrical contacts for a logical signal.
Potentiometer - measures angular positions
continuously, using resistance.
LVDT (linear variable differential transformer) -
measures linear displacement continuously using
magnetic coupling.
When a sensor detects a logical change it must signal that change
to the PLC. This is typically done by switching a voltage or current
on or off. Typical out- puts from sensors (and inputs to PLCs) are
listed below in relative popularity.
1. Sinking/Sourcing - Switches current on or off.
2. Plain Switches - Switches voltage on or off.
3. Solid State Relays - These switch AC outputs.
4. TTL (Transistor Transistor Logic) - Uses 0V and 5V to indicate logic
levels.
PLC inputs must convert a variety of logic levels to the 5Vdc logic
levels used on the data bus. This can be done with circuits similar to
those shown below. Basically the circuits condition the input to
drive an optocoupler . This electrically isolates the external
electrical circuitry from the internal circuitry.
PLC outputs must convert the 5Vdc logic levels on the PLC data bus to
external voltage levels. This can be done with circuits similar to those
shown below. Basically the circuits use an optocoupler to switch
external circuitry. This electrically isolates the external electrical
circuitry from the internal circuitry.
 Gate(-) Gate(+)
Drain(-) Source(+) Drain(+) Source(-)
P P N N

N TYPE SUBSTRATE P TYPE SUBSTRATE

P channel MOSFET N channel MOSFET

D D
G G
S S
 OSI Network Model
The OSI model is a way of describing how
different applications and protocols interact
on network-aware devices.
PHYSICAL LAYER
It’s a set of rules regarding the hardware used to transmit data.
DATALINK LAYER
The physical layer provides the data link layer with bits. Now data layer provides the bit as
data frames - packets, containing data as well as control information.
NETWORK LAYER
The network layer, is concerned with packet switching. It establishes virtual circuits
(Paths between terminals) for data communications. As the sending end, the network
layer repackages messages from the transport layer above it into data packets, so the
lower layers can transmit them.
TRANSPORT LAYER
The Transport layer can detect errors, identify packets that have been sent in the
incorrect order, and then rearrange them.
SESSION LAYER
The session layer is concerned with the management of the network. The user
communicates directly with this layer. It can verify passwords entered by the user. It can
determine who uses the network, for how long, and for what purpose. It controls data
transfers and even handles recovery from system crashes.
PRESENTATION LAYER
This layer is concerned with the network security, file transfers and formatting functions.
At the bit level it is capable of encoding data in a variety of different forms including
ASCII and EBCDIC.

APPLICATION LAYER
The application layer handles messages, remote logons and the responsibility of
network management statistics. At this level are the database management programs,
electronic mail, file server and printer server programs. The operating systems
command and response language.

PROFIBUS is using 3 layers of OSI.

1. Application layer
2. Data link layer
3. Physical layer

TCP/IP(Transmission Control Protocol/Internet Protocol) is a

TRANSPORT LAYER Protocol.

ETHERNET is a DATALINK LAYER Protocol.

 SERIAL COMMUNICATIONS

Serial communications send a single bit at a time between computers. This

only requires a single communication channel, as opposed to 8 channels to
send a byte.
 With only one channel the costs are lower, but the communication rates are
slower. The communication channels are often wire based, but they may also
be can be optical and radio.
 RS-232c is the most common standard that is based on a voltage change
levels. At the sending computer an input will either be true or false.
 To transmit data, the sequence of bits follows a pattern. The transmission
starts at the left hand side. Each bit will be true or false for a fixed period of
time, determined by the transmission speed..
 Various standards of serial communication

 RS232 , RS485 and Ethernet are different Recommended

Standards for Serial Communication.
 RS232 use 3 wires for Transmitting, Receiving and
another as common. This is a full duplex type as Rx from
one side transmit to Tx to another side and back. This is a
point to point communication.
 RS232 use 2 wires . Difference of potential in both the
wires indicate the bit pattern.
 Ethernet uses twisted pair cable . It can be both full
duplex or half duplex. Its packet look like this.

IP Add IP Add
Data bits
Head-end Tail-end
 Modbus RTU
• MODBUS is considered an application layer messaging protocol, providing
Master/Slave communication between devices connected together through buses or
networks.

• Modbus RTU is an open, serial (RS-232 or RS-485) protocol derived from the
Master/Slave architecture. It is a widely accepted protocol due to its ease of use and
reliability.

• MODBUS RTU packets are only intended to send data.RTU means Remote Terminal
Unit.

• A Remote Terminal Unit (RTU) is a microprocessor-controlled ectronic device that

interfaces objects in the physical world to a distributed control system or SCADA
(supervisory control and data acquisition system) by transmitting telemetry data to the
system and/or altering the state of connected objects based on control messages
received from the system.
 Modbus RTU
• In Modbus RTU using RS-485 there can be only one Master
as there will be only 2 Wire of serial communication.
• Data representation can be with Resistors(combination of
Flip-flops).
• Designer allocates some memory to the some no of
resistors.
• Data packet will look like

ID FC ADD of data resistors Data CRC

Address of Slave Function

on network Code(read/write)

When master sends this packet the slave interpret t

correctly and respond accordingly.
 Modbus TCP
• In Ethernet lowest level is one node in ethernet to
another.
IP IP
Data
Header Tailer
• In the data field the receiver does not find out the data
type(ascii/32 bit binary/barcode etc.)
• Hence we need an application layer protocol for implicit
understanding. So modbus TCP.
IP TCP TCP IP
FC ADDRESS LENGTH DATA
Header HEADER TAILER Tailer

TCP checks FC &

No of
decide
Resistors
read/write
• In Modbus TCP Both Side Communication(full duplex) can
be possible.
PROFIBUS DP
 PROFIBUS Wiring

• Twisted shielded pair copper cable

• Fiber optic components.
PROFIBUS DP CABLE (SHIELDED TWSITED PAIR)
•PROFIBUS DP uses high and low voltage to represent each bit . When
nothing is transmitted, the voltage is high. The 8 bits of data are
packed in packages of 11 bits as shown above .
• After the data bits and before the stop bit, the package has a parity
bit. This bit is set to 1 (high) or 0 (low) depending on the number of
ones in the data word – and so that there always are an odd number
of ones among the 11 bits of the package. The station that receives
the package can then check for the number of ones and in that way
check if errors have occured during transmission.
Each PROFIBUS station is given a unique address which should
be a number between 0 and 126. This means that it can never
be more than 127 stations in a network. If the cables are long or
the number of stations exceeds 32, it is a need for repeaters.
Each segment has to be terminated in each end – see the
picture above.
The Token Passing telegram is three octets = 33 bits.
The FDL Status Request telegram is 6 octets = 66 bits.
The Data Telegram has a head of 9 octets = 99 bits and a tale
of 2 octets = 22 bits.
A SIMPLE LADDER LOGIC
Control operation(RECLAIMATION)
TRAVELLING
TRIPPER
POSITIONING

BCN1/A NO
Conveyor
READYNESS
PCMU,BSMU,ZSS,
OLR
YES
NO
CC 8A/8A1
READYNESS
PCMU,BSMU,ZSS,
YES OLR
START
CC-8A/8A1

VIBROFEEDER
READYNESS

YES
START
VIBROFEEDER(6)

JH-18 SILO
LEVEL SENSOR
(MORE THAN
80%)

NO
 NO
CC 7A/7B
NO
READYNESS

YES PCMU,BSMU,ZSS,
OLR
START
CC-7A/7B

CC 6A/6B
NO
READYNESS

PCMU,BSMU,ZSS,
YES OLR
START
CC-6A/6B

YC-3
NO
READYNESS

PCMU,BSMU,ZSS,
YES OLR
 YES
SCR-1
NO
READYNESS

ALL INTERLOCKS OF
YES SCR HEALTHY
START BOOM
CONVEYOR &
BUCKETWHEEL
THANK YOU