lignite transferring system using microcontroller

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Int. J. Elec&Electr.Eng&Telecoms. 2013 M Sowmiya et al., 2013

LIGNITE TRANSFERRING SYSTEM USINGMICROCONTROLLER

M Sowmiya1*, C Keerthika1 and Aysha G V1

*Corresponding Author: M Sowmiya, [email protected]

This paper entitled “lignite Handling System through MICROCONTROLLER” is performed toestablish the remote operation of conveyors in the Fuel Handling System for transferring thelignite from lignite stockpile to bunkers for every shift. The usual practice for this purpose is touse a number of relays which makes the circuit very complex. So MicroLogix1500 controller isused to reduce the circuit complexity, problems related with conventional relay logic system. wecan overcome the manual operation by fully Automation, microcontroller is used to operate themachine in individual drive operation mode and Automatic operation mode. Using Indications,Interlocks and Alarm, made the system as a user friendly model.

Keywords: Lignite handling system, Microcontroller, MicroLogix1500, Manual/automatic

INTRODUCTIONThe ST-CMS 250 MW Plant is the first biggestLignite fired plant as a single unit ofIndependent Power producer category in India.It is located at Uthangal, 40 KM west ofCuddalore, 12KM from Neyveli Township to thewest of NLC TPS-II (Thermal Power Station-II)and to the north of Railway Line toVridhachalam. The plant is designed tooperate continuously at 104% TMCR(overpressure mode operation). That meansto generate 260 MW gross electrical. The unitis designed for base load conditions. Ligniteis unloaded into Railway wagons by means ofhydraulic operated retractable chutes. It is

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Int. J. Elec&Electr.Eng&Telecoms. 2013

1 E&I Department, Bharath Institute of Science and Technology, 173, Agharam Road, Selaiyur, Chennai 60007, India.

designed to transport 2500 tons of lignite perrack of 58 wagons. Lignite from the wagons isunloaded to the ground hoppers locatedadjacent to Power Plant from where it istransported by Belt Conveyors to Surgehopper located inside the Power Plant. Fromthe surge hoppers lignite can be fed to conicalstockpile or to the conveyors (1A/1B) feedinglignite to Boiler Bunkers. Estimatedconsumption of lignite for the power plant perday is 6000 tons.

This paper is mainly deals to design theLignite Transferring System in microcontrollerbased control system by using micrologix 1500controller, and compairing the New

Research Paper

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methodology with the existing one. TheRSLogix Micro programming software allowsto create, modify and monitor applicationprograms for the Allen-Bradley MicroLogicfamiy of controllers. It is designed to increaseproductivity and helps to save time, maximiseperformance, save project development time,and reduce the total cost of ownership of asystem

EXISTING SYSTEM GENERALOVERVIEWThe ST-CMS 250 MW Plant is the first biggestLignite fired plant as a single unit ofIndependent Power producer category in India.It is located at Uthangal, 40 KM west ofCuddalore, 12 KM from Neyveli Township tothe west of NLC TPS-II (Thermal PowerStation-II) and to the north of Railway Line toVridhachalam. The nearest Railway Stationu.mangalam is at a distance of 5KM and theCuddalore-Vridhachalam highway is at 4 KMfrom site. The plant is located in close proximityto the existing Mine-1 and Mine-II of NLC(Neyveli Lignite Corporation). The plant isdesigned for a guaranteed. Net ElectricalOutput of 227.5 MW On the PerformanceGuarantee Basis. The plant is designed tooperate continuously at 104% TMCR(overpressure mode operation). That meansto generate 260MW gross electrical. The unitis designed for base load conditions.

The Lignite Handling System of ST-CMSstocks from stock yard and it runs up to theBunker. It is used to transfer the lignite fromstorage yard to bunker bay by means ofconveyor. In stock yard to grounder hopperLignite is fed through pay loader and truck.

Lignite from the circular pile can bestacked in the rectangular stockpile of 35,000

T capacities (160 M long and 50 M wide).About 1000 to 1200 tons per day of lignite isretrieved from this stockpile and fed to theground hopper. Equal quantity of fresh ligniteis transferred from the circular stockpile torectangular pile. In this way the lignite in therectangular stockpile gets replenished withfresh lignite in one-month period, whichavoids quality deterioration due to long timestorage.

Figure 1: Block Diagramfor Existing System

The lignite from the circular pile/rectangularpile is fed in to the ground hopper of 150 tcapacity by trucks. From the ground hopperthe lignite is reclaimed by two RotaryDischarge Machines of 600 T/Hr capacitywhich feeds to two streams of plant conveyors1A, 1B. The conveyors 1A, 1B feeds the ligniteto Crushers for size reduction (from 250 mmto 50 mm) .Tramp metals shall be removed byIn Line Magnetic Separators installed prior toand post crushing. Crushed lignite is thenconveyed to boiler bunker at 38 M elevationthrough belt conveyors 2A, 2B, 3A, 3B andshuttle conveyors SC/1, SC/2. The GeneralOverview of the Lignite

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OVERVIEW OFMICROCONTROLLERA Microcontroller or PLC, is more or less atiny computer with a built-in Operating System(OS). This OS is highly specialized to handleincoming events in real time, i.e., at the timeof their occurrence. The Microcontroller hasinput lines where sensors are connected tonotify upon events and it has output lines tosignal any reaction to the incoming Thesystem is user programmable. It uses alanguage called “Relay Ladder” or “RelayLadder Logic”. The name of this languageimplies the fact that the control logic of theearlier days, which was built from relays, isbeing simulated.

The Microcontroller is primarily used tocontrol machinery. A program is written for theMicrocontroller which turns on and off outputsbased on input conditions and the internalprogram. In this aspect, a Microcontroller issimilar to a computer. However, aMicrocontroller is designed to be programmedonce, and run repeatedly as needed. In fact, acrafty programmer could use a Microcontrollerto control not only simple devices such as agarage door opener, but their whole house,including turning lights on and off at certaintimes, monitoring a custom built securitysystem, etc.

When the first electronic machine controlswere designed, they used relays to control themachine logic A basic machine might need awall covered in relays to control all of itsfunctions. There are a few limitations to thistype of control.

• Relays fail.

• The delay when the relay turns on/off.

• There is an entire wall of relays to design/wire/troubleshoot.

A Microcontroller overcomes theselimitations; it is a machine controlled operation.

FEATURES – MICROLOGIX1500• 7 KB memory (3.65 KB user program with

4 KB user data) on the 1764-LSP.

• 14 KB memory (10 KB user program with4 KB user data) on the 1764-LRP.

• Two-piece design with small footprint;processor and base unit slide together toform complete controller.

• Processor and base unit are independentlyreplaceable.

• Base unit includes power supply and isavailable with three different configurationsof embedded I/O.

• Optional Data Access Tool (1764-DAT) letsyou change integer and bit values within thecontroller.

• Includes eight high-speed inputs that youcan use individually as latching inputs.

• Includes two high-speed outputs that youcan configure as pulse train output or aspulse width modulated outputs (only oncontrollers with embedded 24V DCoutputs).

• Compatible with 1769 Compact I/Omodules (up to 16 modules using anadditional bank of expansion I/O and anexpansion power supply).

A Microcontroller based control systemconsists of:

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• Sensing inputs or controlling hardware.

• Microcontroller input hardware.

• The controller or CPU.

• Handheld programming device or personalcomputer.

• Output Microcontroller hardware.

• Hardware output devices.

DESIGN• Select an instrument/system that to be

controlled.

• Specify all input and output instruments thatwill be connected to a Microcontroller.

• Make a ladder diagram for a program byfollowing the sequence of operations thatwas determined in the first step.

COMMUNICATIONRS-232-C: The built-in RS-232-C portsupports DF1 full-duplex, DF1 half-duplexslave, new DH1 half-duplex master, DH-485,Modbus RTU slave and new Modbus RTUmaster protocols, report-by-exception, andpeer-to-peer data exchange. This port can beused for direct connection of programming andoperator interface devices (e.g., a personalcomputer), and supports dial-in remoteprogramming.

ASCII: A full ASCII command set for the RS-232-C port allows read and write with ASCIIdevices.

FUTURE ENHANCEMENT• The lignite transferring system may be

modified to higher version forprogrammable logic controller.

• We can design to operate more than oneconveyor scheme with full protection withprogrammable logic controllers.

• The system performance to be analysis asper the inputs from local using byprogrammable logic controller.

• Further improvement in the design of thesystem to be operates through in remotemode by using DCS.

Figure 2: Block Diagram of Microcontroller

APPLICATIONSTypical applications for the MicroLogix™programmable controllers include:

• Material Handling

• Packaging Applications

• General Industrial Machinery

• Printing

• Food and Beverage

• Pharmaceutical

• Water Wastewater/SCADA

• Clutch/Brake control

• Position Control – Pick-and-place/Conveyor

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CONCLUSIONThis paper is very useful for automaticoperation of Lignite transferring system;

• To reduce the manpower cost (localoperator).

• The safe operation of conveyor by interlockand protection (PCS, BSS, ZSS).

• To reduce the time (to start system one byone).

ACKNOWLEDGMENTI take this opportunity to express my sinceregratitude to Principal of Bharath Institute ofHigher Education and Research who havecontributed in making the work a greatsuccess. I express gratitude to my guide.Prof. M Bharathi who constant help andencouragement support me to complete mywork.

REFERENCES1. Alstom-babcock Borsig Power

Document Reference Number:1BYE176040.

2. Microcontroller document referencenumber:www.rockwellautomation.com

Figure 3: Flow Chart Lignite TransferringSystem

Figure 4: Lignite Handling SystemThro Microcontroller

lignite transferring system using microcontroller

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