Automation of Batch process

Using
Programmable Logic Controller (PLC)

Advisor:
Engr. Yasir Anwar Lecturer UCE&T, Bahauddin Zakriya university Multan
Final year project, session 2005-2009
Muhammad Ishtiaq 2005-CPE-10
Sidra Naseer 2005-CPE-11
Asad Abbas 2005-CPE-03
Shahbaz Hussain Baloch 2005-CPE-21

Department of Computer Engineering
University College of Engineering & Technology
Bahauddin Zakriya University Multan
Department of Computer Engineering

The undersigned hereby certify that students have read and award a pass in Department of Computer
Engineering, University College of Engineering & Technology, Bahauddin Zakriya University for the
project entitled
Automation of Batch process Using Programmable Logic Controller (PLC)
In partial fulfillment of the requirement for the degree of B.Sc. Computer Engineering.






------------------------------------------ -------------------------------------------
Engr. Yasir Anwar External Examiner
(Lecturer)
Department of Computer Engineering
UCE&T BZU, Multan



Dedication Dedication Dedication Dedication


To
Our beloved parents
Whose efforts, prayers
&
Wishes have been an Inspiration




ACKNOWLEDGMENT ACKNOWLEDGMENT ACKNOWLEDGMENT ACKNOWLEDGMENT

we are grateful to ALLAH ALMIGHTY the most merciful, the most beneficent, who is entire source of
knowledge and wisdom, who bestowed us health, abilities and guidance to complete the project in a
successful manner.
we would like to acknowledge our project advisor Engr. yasir anwar for his support and efforts. He was
always there to guide us whenever we felt stuck off and his encouragement always worked as moral
booster for us.
We are thankful to Engr.Ahsan Khalil for his encouragement and guidance.













Abstract Abstract Abstract Abstract
This project focused on the understanding and experiencing programmable Logic controller
programming Ladder Logic. programmable Logic controller is widely used in industries for
controlling different parameters. we implement the automation of batch process by controlling
different instruments and devices with help of programmable Logic controller.
Batch process is a process that leads to the production of finite quantities of material by
subjecting quantities of input materials to an ordered set of processing activities over a finite
period of time using one or more pieces of equipment. Batch process is common in bakeries and
in the manufacture of sports shoes, pharmaceutical ingredients , food manufacturing, inks, paint
and adhesives. The problems is batch process are the majority of industry is using manual thats
efficiency is dependent on operator. These are time consuming, have low production and high
cost. For these problems we have to automate the process by using PLC. Programmable Logic
Controller (PLC) is a digital device, which uses programmable memory that coordinates several
input and output devices to control different processes. For automation of batch process using
PLC we have to control three phase induction motors, water pump through press control,
thermocouple, heating device, and pneumatic valves. For automating the batch process in candy
preparation industry.





Table of contents Table of contents Table of contents Table of contents
1 AUTOMATION..
1.1 BASIC COMPONENTS OF AUTOMATION..
1.2 TYPES OF AUTOMATION.
1.3 PROBLEM STATEMENT (BATCH PROCESS).
1.4 INSTRUMENTS OVERVIEW IN AUTOMATION ...........
2 BATCH PROCESS
2.1 INTRODUCTION TO BATCH P ROCESS
2.2 BATCH PROCESS AUTOMATION..
2.3 REASONS TO AUTOMATE BATCH PROCESS.
2.4 STANDARDS FOR BATCH CONTROL...
2.5 CONSIDERATION OF S88 STANDARD
2.6 AUTOMATION OF BATCH PROCESS WITH PLC
2.7 REQUIREMENTS FOR AUTOMATING BATCH PROCESS
CONTROL WITH PLC
3 PROGRAMMABLE LOGIC CONTROLLER.
3.1 INTRODUCTION ....
3.2 THE ROLE OF PLC.
3.3 PLC BASICS.
3.4 CONSTRUCTION OF A PLC
3.5 PLC ATCHITECTURE..
3.6 CHARACTERISTIC FUNCTIONS OF A PLC.....
3.7 TYPES OF PLC
3.8 DESCRIPTION OF THE PLC SOFTWARE.
3.9 PLC PROGRAMMING....
3.10 SPECIFICATION OF DELTA DVP-SS
4 WPL SOFTWARE
4.1 SYSTEM REQUIREMENT
4.2 INSTALLATION AND PROGRAM EXECUTION.
4.3 SETUP.
4.4 LADDER DIAGRAM MODE
4.5 INSTRUCTION MODE..
4.6 EDITING COMMENTS..
4.7 COMMUNICATION...
4.8 SFC EDITING ENVIRONMENT
4.9 SIMULATOR..
5 INSTRUMENTS & DEVICES.
5.1 PRESS CONTROL..
5.2 THREE PHASE INDUCTION MOTOR.
5.3 FREQUENCY INVERTER..........
5.4 PNEUMATIC VALVE
5.5 THERMOCOUPLE.
5.6 TEMPERURE CONTROLLER..
6 DESIGN & IMPLIMENTATION
6.1 CONTROLLER PHILOSOPHY.
6.2 MAIN FUNCTIONS T AUTOMATE.
6.3 PROJECT DIAGRAMS..
6.4 IMPLEMENTATION OF FUNCTIONS



List of Figures List of Figures List of Figures List of Figures

Figure 1.1: components of automation
Figure 2.1: classic S95 control hierarchy.
Figure 2.2: S-95 Levels with Applications.
Figure 2.3: Information Exchange Between Levels 3 & 4.
Figure 2.4 Business planning & Logistics.
Figure 2.5: The Concept of Control
Figure 2.6: Separate Recipe and Equipment Control..
Figure 2.7: Everything Breaks Into Pieces..
Figure 2.8: A Recipe Explosion..
Figure 2.9: The Procedural Control Model.
Figure 2.10: A candy Recipe Procedure..
Figure 2.11: The Make Mix Unit Procedure.
Figure3.1: PLC conceptual application diagram
Figure3.2: Model of PLC..
Figure 3.3: Modular PLC I an automated system..
Figure 3.4: Memory and processors in CPU of PLC.
Figure 3.5: The power supply in a plc system...
Figure 3.6: Manually switch controlling of lamp.
Figure 3.7: Product profile and outline.
Figure 3.8: Wirring of Power Terminal
Figure 3.9: input/output wiring.
Figure 4.1 WPL soft..
Figure 4.2 opening Window..
Figure 4.3: Modes of Programming....
Figure 4.4: Example Ladder Diagram.
Figure 4.5: Instruction Mode Window
Figure 4.6: Edit device Comment Window
Figure 4.7: auto-detect the PLC communication
Figure 4.8: sequential function chart editor
Figure 4.9: SFC Environment....
Figure 4.10: SFC Editing Instruction
Figure 4.11: Ladder Monitoring
Figure 4.12: Debug Mode.
Figure 5.1: press control.
Figure 5.2: Component of press control.
Figure 5.3: Installation of pres control ..
Figure 5.4: Electrical wiring of press control.
Figure 5.5: Closed squirrel-cage three-phase motor..
Figure 5.6: Rotor voltage UR is a proportional function of slip s.
Figure 5.7: Operating characteristics of an induction motor.
Figure 5.8: Circuit Diagram of Inverter.
Figure 5.9: circuit configuration ..
Figure 5.10: Pneumatic Valve.
Figure 5.11: Thermocouple
Figure 5.12: Temperature Transmitter
Figure 6.1: Recipe Chart..
Figure 6.2: Block Diagrame project.
Figure 6.3: Model Diagrame
Figure 6.4: process Flow Chart










List of Tables List of Tables List of Tables List of Tables

Table 3.1: Response time of PLC
Table 3.2 Plc specifications..
Table 4.1: Editing the Ladder Diagram
Table 4.2: Shortcuts For Editing..
Table 4.3: SFC Editing.
Table 5.1: Typical synchronous speeds in a 50 Hz circuit..
Table 5.2: Specification of inverter.