Summer Training Report Hindalco Industries Limited

Summer Training Report
3/21/12
INTEGRITY
on Instrumentation in fabrication Plant At Hindalco Industries Submitted By : UNDEFINED

COMMITTMENT PASSION
ECE 7th Sem SEAMLESSNESS
SPEED
INTEGRITY
Hindalco Industries Limited Overview Fabrication / Instrument Department Remelt Shop Extrusion Press Rolling Mill Chemical / P. T. Lab Product Range PLC Basics PLC Simple Programming 3/21/12
COMMITTMENT PASSION
Table of Contents
SEAMLESSNESS
SPEED
Hindalco Industries Limited is the flagship company of one of Indias leading business houses, the Aditya Birla Group. The group has been in operations spanning over 5 decades with global presence. A powerhouse in non-ferrous metals. Hindalco has 2 business activities Aluminium and Copper. Aditya Birla Group Incorporated in 1958. Hindalco commenced production of Aluminium in 1962 at Renukoot, Uttar Pradesh with an initial capacity of 20,000 MTPA of aluminium metal. In 2000 Hindalco acquired a majority stake in Indian Aluminium Company Ltd.
Hindalco - An Overview
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INTEGRITY COMMITTMENT PASSION SEAMLESSNESS SPEED
Hindalco - Integrated Operations

Raw Materials Raw Materials ( Bauxite ) Co- Generation Power By Renusagar Power Plant Caustic Soda Aluminium fluoride
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Instrument Department
Instrumentation Plant is R & D and maintenance Department of Hindalco. Function of Instrument Department is to maintain the Electronic equipment which is used in fabrication Plant and also find the easiest method to do it.
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Remelt Shop
The are various types of shop comes under the Remelt shop like Properzi, Cooling Tower R & D.
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Extrusion Press
Extrusion Press is system that reduces the Diameter of various types of Billet( Solid Aluminium Rod).
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Rolling Mill
Rolling mill is the System which reduces the thickness of the materials and produces thin sheets from slabs.
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Chemical Lab
Chemical Laboratory Finds the various types of alloy combinations and the property of the aluminium after mixing the 3/21/12 INTEGRITY PASSION SEAMLESSNESS SPEED alloy. COMMITTMENT
P. T. Laboratory
P.T. Lab measures the Physical parameter of aluminium and find the various property of aluminium, like breaking strength, tensile strength etc. 3/21/12
Hindalco Product Range
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PLC Basics : Description

This Presentation introduces the basic hardware and software components of a Programmable Controller (PLC). It details the architecture and basic instruction set common to all PLCs. Basic programming techniques and logic designs are covered. This Presentation describes the operating features of the PLC, the advantages of the PLC over hard-wired control systems, practical applications, troubleshooting and maintenance of PLCs.
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Advantages of PLCs
Advantages of PLCs Less wiring. Wiring between devices and relay contacts are done in the PLC program. Easier and faster to make changes. Trouble shooting aids make programming easier and reduce downtime. Reliable components make these likely to operate for years before failure.
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Historical Background
The Hydramatic Division of the General Motors Corporation specified the design criteria for the first programmable controller in 1968. Their primary goal To eliminate the high costs associated with inflexible, relay-controlled systems.
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Programmable Logic Controllers

( Definition according to NEMA standard ICS3-1978)
A digitally operating electronic apparatus which uses a programming memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog modules, various types of machines or process.
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Leading Brands Of PLC

AMERICAN 1. Allen Bradley 2. Gould Modicon 3. Texas Instruments 4. General Electric EUROPEAN 1. Siemens 2. Klockner & Mouller 3. Festo 4. Telemechanique JAPANESE 1. Toshiba 2. Omron 3. Fanuc 4. Mitsubishi
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Areas of Application
Manufacturing / Machining Food / Beverage Metals Power Mining Petrochemical / Chemical
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PLC Size
1. SMALL - it covers units with up to 128 I/Os and memories up to 2 Kbytes. - these PLCs are capable of providing simple to advance levels or machine controls. 2. MEDIUM - have up to 2048 I/Os and memories up to 32 Kbytes. 3. LARGE - the most sophisticated units of the PLC family. They have up to 8192 I/Os and memories up to 750 Kbytes. - can control individual production processes or entire plant.
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Tank Used to Mix Two Liquids

MOTO R
F S
A
SOLENOIDS
FLOAT SWITCH
SOLENOID
C
TIME R
1 -MINUTE
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Major Components of a Common PLC
POWER SUPPLY
From SENSORS
Pushbuttons, contacts, limit switches, etc.
I M N O P D U U T L E
O M PROCESSOR U T P U T O D U L E
To OUTPUT
Solenoids, contactors, alarms etc.
PROGRAMMING DEVICE
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Major Components of a Common PLC

POWER SUPPLY I/O MODULES PROCESSOR PROGRAMMING DEVICE
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I/O Module
DC INPUT MODULE
USE TO DROP THE VOLTAGE TO LOGIC LEVEL IS NEEDED TO: Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise
FROM INPUT DEVICE
Current Limitin g Resisto r
OPTOISOLATO R
Buffer, Filter, hysteresis Circuits
TO PROCESSOR
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I/O Module
DC / AC OUTPUT MODULE
IS NEEDED TO: Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise
FROM PROCESSOR
TTL Circuits
OPTOISOLATO R
Amplifier RELAY TRIAC RESISTO R
TO OUTPUT DEVICE
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INPUT / OUTPUT
INPUTS OUTPUTS
MOTOR CONTACTOR PUSHBUTTONS
PLC
LAMP
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PLC Connection
L2 L1
CONTACTOR N. O
L2 L1 FIELD WIRING
MOTOR SOLENOID VALVES LAMP BUZZER
L1
OUTPUT MODULE WIRING
O: 4 0
PASSION
L2
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INTEGRITY
CONTACTO R
COMMITTMENT
SEAMLESSNESS
SPEED
Discrete Input
A discrete input also referred as digital input is an input that is either ON or OFF are connected to the PLC digital input. In the ON condition it is referred to as logic 1 or a logic high and in the OFF condition maybe referred to as logic o or logic low.
Normally Open Pushbutton Normally Closed Pushbutton Normally Open switch Normally Closed switch Normally Open contact Normally closed 3/21/12 contact INTEGRITY COMMITTMENT
PASSION
SEAMLESSNESS
SPEED
IN
OFF Logic 0
PLC Input Module

24 V dc
IN
OFF Logic 1
PLC Input Module

24 V dc
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Analog Input
An analog input is an input signal that has a continuous signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA or 0 to 10V. Below, a level transmitter monitors the level of liquid in the tank. Depending on the level Tx, the signal to the PLC can either increase or decrease as the level increases or decreases.
Level Transmitter
IN
Tan k
PLC Analog Input Module
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Digital Output
A Digital output is either in an ON or OFF condition. Solenoids, contactors coils, lamps are example of devices connected to the Discrete or digital outputs. Below, the lamp can be turned ON or OFF by the PLC output it is connected to.
OUT
PLC Digital Output Module
Lamp
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Analog Output
An analog output is an output signal that has a continuous signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V.
Electric to pneumatic transducer
OUT E
PLC Analog Output Module
0 to 10V
Supply air
Pneumatic control valve
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Basic Function of PLC

While the PLC is running, the scanning process includes the following four phases, which are repeated continuously as individual cycles of operation:
PHASE 1
Read Inputs Scan

PHASE 2
Program Execution
PHASE 3
Diagnostics/ Comm
PHASE 4
Output Scan
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Selecting a PLC
Criteria Number of logical inputs and outputs. Memory Number of special I/O modules Scan Time Communications Software
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PLC Programming Software

Examples of PLC Programming Software: 1. Allen-Bradley Rockwell Software RSLogix500 2. Modicon - Modsoft 3. Omron - Syswin 4. GE-Fanuc Series 6 LogicMaster6 5. Square D- PowerLogic 6. Texas Instruments Simatic 6. Telemecanique Modicon TSX Micro
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PROGRAMMING
Normally Open (NO)
Normally Closed (NC)
Power flows through these contacts when they are closed. The normally open (NO) is true when the input or output status bit controlling the contact is 1. The normally closed (NC) is true when the input or output status bit controlling the contact is 0.
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Coil s Coils represent relays that are energized when power flows to them. When a coil is energized it causes a corresponding output to turn on by changing the state of the status bit controlling the output to 1. That same output status bit maybe used to control normally open or normally closed contact anywhere in the program.
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AND OPERATION
A Rung C B
Each rung or network on a ladder program represents a logic operation. In the rung above, both inputs A and B must be true (1) in order for the output C to be true (1).
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OR OPERATION
A Rung B In the rung above, it can be seen that either input A or B is be true (1), or both are true, then the output C is true (1). C
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NOT OPERATION
A Rung C
In the rung above, it can be seen that if input A is be true (1), then the output C is true (0) or when A is (0), output C is 1.
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References
Hindalco Works Library www.hindalco.com www.adityabirla.com en.wikipedia.org/wiki/Aditya_Birla_Group en.wikipedia.org/wiki/Hindalco_Industries en.wikipedia.org/wiki/Programmable_logic_con troller en.wikipedia.org/wiki/PLC program-plc.blogspot.com
3/21/12
Thank You !
Thank You For Giving Your Valuable Time !
3/21/12

Summer Training Report Hindalco Industries Limited

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Summer Training Report Hindalco Industries Limited

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Summer Training Report

on Instrumentation in fabrication Plant At Hindalco Industries Submitted By : UNDEFINED

ECE 7th Sem SEAMLESSNESS

Hindalco - Integrated Operations

Hindalco Product Range

PLC Basics : Description

Programmable Logic Controllers

Leading Brands Of PLC

Tank Used to Mix Two Liquids

Major Components of a Common PLC

Major Components of a Common PLC

FROM INPUT DEVICE

Current Limitin g Resisto r

Buffer, Filter, hysteresis Circuits

Amplifier RELAY TRIAC RESISTO R

MOTOR CONTACTOR PUSHBUTTONS

MOTOR SOLENOID VALVES LAMP BUZZER

OUTPUT MODULE WIRING

PLC Input Module

PLC Input Module

PLC Analog Input Module

PLC Digital Output Module

PLC Analog Output Module

Pneumatic control valve

Basic Function of PLC

Read Inputs Scan

PLC Programming Software

Normally Open (NO)

Normally Closed (NC)

Thank You For Giving Your Valuable Time !

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