automation(ebtsl)

An AUTOMATION Perspectiveof

ESSAR BULK TERMINAL SALAYA LIMITED

SILO

JH-16

JH14

JH15

JH17

JH18 (SILO)

JNT1

EPGL (BUNKER)

JH12

JH13JH-8

JH09

JH11

JH10

JH19JNT1

JH-7

VPCL

JH-1SUL

SL SUL

JH-6

JH-5

JH-4 JH-3

JH-2

ER-2 Near JH-17

SS-1A Near JH-6

SS-1 Near JH-

2

DG SET DG SET

MOTORSTRANSFORMER MOTORSTRANSFORMER TRANSFORMER MOTORS

1)DTR 2 x 25 MVA (33/11),2 x 1.5 MVA(11/.433),2 x 1.2 MVA(11/.72)2)CTR2 x 2.0 MVA (11/.72/.72)3) LIGHTING TR1 x 300 KVA(.415/.380)

1)6 x 200 KW(VFD) for YC-1,2,3(2 each) in JH-12,13,14 respectively.2)2 x 200 KW(DOL) for CC-6A,6B(1 each) in JH-17.3) 2 x 5.5 KW FG in JH-124)2 x 5.5 KW FG in JH-13,14(1 each)5)2 x 5.5 KW FG in JH-156)2 x 5.5 KW FG in JH-17

1)DTR 2 x 7.5 MVA(33/11),2 x 0.5 MVA(11/.433)2)CTR2 x 2.5 MVA (11/.72/.72)4) LIGHTING TR1 x 100 KVA(.415/.380)

1)1 x 900 KW(VFD) for CPCC-2 in JH-62)1 x 700 KW(VFD) for CC-4 in JH-6

1)DTR 2 x 25 MVA (33/11),2 x 1.5 MVA(11/.433) 2)CTR2 x 2.5 MVA (11/.72/.72)3) LIGHTING TR1 x 200 KVA(.415/.380)

1)2 x 200 KW(VFD) for PCC-6,PCC-5(1 each) in JH-1,2 respectively.2)2 x 500 KW(VFD) for CC-1,2(1 each) in JH-2,3 respectively.3) 1 x 150 KW(VFD)for CC-2 in JH-3.

SS-2 Near JH-8

TRANSFORMER MOTORS

DG SET

1)DTR 2 x 1.5 MVA(11/.433),2 x 2.5 MVA(11/.72)2)CTR2 x 4.0 MVA (11/.72/.72)3) LIGHTING TR1 x 350 KVA(.415/.380)

1)3 x 900 KW(VFD) for CPCC-2 in JH-82)2 x 200 KW(DOL) for CC-5A,5B(1 each) in JH-11.3) 1 x 200 KW(DOL) for PCC-1 in JH-164)1 x 150 KW(DOL) for PCC-2 in JH-75)6 x 18.5 KW for RBF in JH-86)6 x 5.5 KW FG in JH-8(2),9(2),10(2)7)1 x 150 KW(DOL)for EFC

1)DTR 2 x 0.5 MVA(11/.433) 2)CTR2 x 3.5 MVA (11/.72/.72)3) LIGHTING TR1 x 100 KVA(.415/.380)

1)2 x 900 KW(VFD) for CPCC-1 in JH-52)1 x 250 KW(VFD) for PCC-3 in JH-5.


1)1 x 900 KW(VFD) for CPCC-2 in JH-6A


1)1 x 900 KW(VFD) for CPCC-1 in JH-42)1 x 400 KW(VFD) for CC-3 in JH-4.

ER-1A Near JH-5

ER-1B Near JH-6A

TRANSFORMER MOTORS TRANSFORMER MOTORS

ER-1 Near JH-4

TRANSFORMER MOTORS

100 KVA

400 KVA

DG SET160 KVA

DG SET

30 KVA

FCPU-1 FCPU-2

RIO-1

FCPU-3 FCPU-4 FCPU-5 FCPU-6

RIO-2A RIO-2B RIO-3BRIO-3A

SS-1

ER-1BER-1AER-1

ER-1A SS-2 ER-2 ER-3 ER-4

FCPU-4

CONTOL ROOM

HMI (52’’ LCD

DISPLAY,OPERATING STATIONS)L

IU

LIU

10-100 mbps ETHERNET

FIBRE OPTICS(FO) CABLE

CI86

7

PM86

4A

CI85

4A

PM86

4A

CI86

7CI

853

CI85

4A

SCR-1,2,3,4 PCMU,

BSMU,ZSC,

RELAY

EM, FDAS, UPS

MOD BUS TCPMOD BUS RTU

CI84

0CI

840

CI84

0CI

840

DI8

10D

I810

AI81

0AI

810

DO

810

AO81

0D

I810

DO

810

AI81

0

DI8

10D

I810

AI81

0AI

810

DO

810

AO81

0D

I810

DO

810

AI81

0

I/O CLUSTERS

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.

Optional up to 12 Communication modules

AC 800M Architecture

Redundant Ethernet 2 RS-232 channels

CPU S800L I/O

Totally can up to 96 S800 I/O modules be connected as direct I/O to AC800MUp to 12 I/O modules can directly be connected to the CPU via the electrical ModulebusUp to 84 I/O modules can be connected via I/O clusters via the optical Modulebus

Compact Flash slot

Max 12 S800 modules per I/O Cluster

< 1000m

Up to 48 Controllers on Control Network

Max 12 Communication modules on CEX bus

Flexible and scalable in size and performance

Control Network (Ethernet TCP/IP, 10Mbps)

Max 12 S800 modules on Electrical Modulebus

Max 24 S800 modules per remote I/O station

Remote S800 I/O via PROFIBUS DP/V1

Max 7 S800 I/O Clusters

OpticalModuleBus

I/O Cluster

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

AC 800M Open Architecture

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

RS23

2CI

853

PRO

FIBU

S D

PCI

854

MB3

00CI

855

S100

I/O

CI85

6

INSU

MCI

857

Driv

eBus

CI85

8

Cont

rol

Net

wor

kRS

232

PM8x

x

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 outputs 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.

N TYPE SUBSTRATE P TYPE SUBSTRATE

P P N N

P channel MOSFET N channel MOSFET

Gate(-) Gate(+)Drain(-) Source(+) Source(-)Drain(+)

G

D

S

G

D

S

The OSI model is a way of describing how different applications and protocols interacton network-aware devices.

OSI Network Model

It’s a set of rules regarding the hardware used to transmit data.

PHYSICAL LAYER

DATALINK LAYER

NETWORK LAYER

TRANSPORT LAYER

SESSION 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.

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.

The Transport layer can detect errors, identify packets that have been sent in the incorrect order, and then rearrange them.

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

APPLICATION 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.

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 layer2. Data link layer3. 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..

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.

Various standards of serial communication

IP Add Head-end Data bits IP Add

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 likeID FC ADD of data resistors Data CRC

Address of Slave on network

Function 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.

• 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 Header

IP TailerData

IP Header DATAFCTCP

HEADER ADDRESS LENGTH TCP TAILER

IP Tailer

No of Resistors

TCP checks FC & decide 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 Conveyor

READYNESS

PCMU,BSMU,ZSS, OLR

YES

NO

YES

NO

PCMU,BSMU,ZSS, OLR

CC 8A/8A1 READYNESS

START CC-8A/8A1

VIBROFEEDER READYNESS

YESSTART

VIBROFEEDER(6)

JH-18 SILO LEVEL SENSOR (MORE THAN

80%)

NO

NOCC 7A/7B

READYNESS

PCMU,BSMU,ZSS, OLR

NO

YESSTART

CC-7A/7B

CC 6A/6B READYNESS

YES

NO

PCMU,BSMU,ZSS, OLR

START CC-6A/6B

YC-3 READYNESS

NO

PCMU,BSMU,ZSS, OLRYES

YES

SCR-1 READYNESS

NO

ALL INTERLOCKS OF SCR HEALTHYYES

START BOOM CONVEYOR &

BUCKETWHEEL

THANK YOU

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