rino batching plant automation project

RINO BATCHING PLANT AUTOMATION PROJECT

CUSTOMER

FUJAIRAH CONCRETE PRODUCTS

COMPLETION DATE

10/19/2011

PROJECT ENGINEER

Chinthana Dinesh WickramaArachchi

DEPARTMENT

Industrial Automation

DOCUMENT TITLE

System getting started guide

DOCUMENT NO

PRJ-FJRC01-D02-V

Deira General Marketing : P.O. BOX 11370 : DUBAI – UAE : TEL- 00971 4 2545777 : FAX – 00971 4 2545559 : EMAIL: [email protected] : WEB – www.dgm-aws.com

1. OVERVIEW OF PLANT

14

16

11

7

13

17

8

9

10

12

15

26

MIXER

3

4

1

2

5

6

4

3

2

5

1

21

20

52

18

19

1.1 Aggregate Bins Plant consists of five aggregate bins (5) to fill with different aggregates with different particle sizes. Common numbering method for aggregate bins is right to left. I.e.: Right most bin is number one (“1”).

1.2 Aggregate control gates (6) Each aggregate Bin having pneumatic controlled gate for control amount of material drawn from the aggregate bin. Double active pneumatic cylinder with spring return 3/2 solenoid operated pneumatic valve operates the gate. And also each gate having a inductive sensor for detect closed state of the gate. Common numbering method for gates and limit switches is right to left. I.e.: Right most gate is gate no one (“1”) and Right most limit switch is limit switch no one (“1”)

1.3 Weighing Conveyor (2) The amount of material drawn from each bin supposed to measure using weighing conveyor. Conveyor driven by three phase induction motor (1) and hang by four load cells. Conveyor should free from foreign objects for error free operation.

1.4 Transfer Conveyor (4) This conveyor transfers the material from weighing conveyor to mixer. And not suppose to control by PLC and it is supposed to run all the time whenever the plant operating.

1.5 Mixer Mixer consists with aggregates input hopper with vibrator, mixer (8) and mixer door (9) with vibrator. Aggregate input hopper vibrator supposes to operate when the material transferring to mixer and mixer door vibrator and hydraulic pump will operate with mixer gate open signal. Also the mixer door open operation interlocks with mixed material transfer conveyor. Mixer motor also not supposes to control by PLC and it has to run all the time whenever the plant is operating.

1.6 Chemical dispenser Chemical dispenser is a standalone unit and supposes to dispense preset amount of chemical with a 24VDC pulse received from PLC.

1.7 Water Water pump controlled by separate electrical panel and the volume of water flowing into the mixer is measured by a liquid pulse meter and controlled by a solenoid operated pneumatic value. For this pulse meter 2 pulses equals to 1L of water.

1.8 Cement Weighing Bin (12) Cement weighing bin measures the amount of cement dispatch into the mixer and it is hang by three load cells. And cement dispatch controlled by pneumatic operated gate.

1.9 Cement Silos and Screws (14) (15) (16) (17) (18) (19) (20) (21) Cement silos cement loading is a separate system and two screw conveyors are connected to transfer cement from silo to cement weighing bin.

2 Sequence of operation

2.1 System start

2.1 Aggregate Weighing Feed weighing used as the weighing method and the amounts of aggregate have to drawn

from each bin is set by the recipe. Weighing process starts from the first bin and sequence

going up to fifth bin. When starting weighing of any bin it sets the Weighing incomplete flag

for monitor the state of sequence and clears the flag with completion of the weighing for

each bin. Freefall compensation function in CJ1W-F159 weighing module used for

automatically correct fluctuations of freefall of materials. This freefall compensation value

has to set as a weighing setting parameter for the system. With the completion of whole

process it will set the aggregate weighing complete flag.

2.2 Cement Weighing The amount of cement, the cement silo used to drawn cement selected by the recipe and

cement transfer screw will operate with respect to the silo. Cement and aggregate weighing

processes are simultaneous operations. Freefall compensation function in CJ1W-F159

weighing module used for automatically correct fluctuations of freefall of materials. This

freefall compensation value has to set as a weighing setting parameter for the system. With

the completion of weighing process it will set the cement weighing complete flag.

SYSTEM

START

CONTROL

POWER

ON

SET SYSTEM

READY BIT

CON. POWER NOT

DETECTED ALARM EMEGENCY

ENABLED

Cycle

Start

System

Ready

Set Cycle

start Bit

System Not

ready Alarm

Set Next Cycle

disable bit

Clear Error

Flags

Last Cycle

Error free

Last Cycle

Error Alarm

Weighing

Conveyor

Stopped AND

All gates closed

Bin Selection

Enabled Flag

Set Aggregate

weighing start

flag

Weighing Con.

not stopped

Alarm.

AND

CMNT W.

Bin Gate

Closed

Set Cement

weighing start

flag

Weighing Con.

not stopped

Alarm.

Bin Selection

Enabled Flag

Normal

Sequence

Select Cement

Silo 1

Select Aggregate

bin1

BIN 1

FF.CPS

REACHED

GATE 1 CLOSE

ERROR

GATE 1

CLOSED

CLOSE GATE 2

GATE 2

CLOSED

OPEN GATE 1

SILO 1

FF.CPS

REACHED

START SCREW

1

STOP SCREW

1

SILO2

FF.CPS

REACHED

STOP SCREW

2

CLOSE GATE 1

OPEN GATE 2

BIN2

FF.CPS

REACHED

START SREW 2

CEMENT WEIGHING

COMPLETED

2.3 Transfer material to Mixer This operation interlocks with weighing process and mixing process before transfer the

material it will wait for completion flag of Aggregate Weighing, Cement Weighing, Mixing,

and Transfer Conveyor running status bit, Mixer motor running status bit and mixer gate has

to be closed. After the transfer of material next cycle call indicator will activate and i.e.:

system is ready for start weighing of new batch. And immediately mixing process will start.

2.4 Mixing Mixing process has two steps,

I. Dry mixing

Pre defined time duration allocated for dry mixing process and after this time out

water and chemical will add to the mixer.

II. Wet mixing

The amount of water will decide by selected recipe and operator has freedom to add

additional 2L volume of water by pressing manual water button in the panel. Wet

mixing has predefined time duration and after this timeout mix ready flag will set

and depending on the hydraulic press machine state mix transfer process will start.

3 Basic operation procedure

3.1 Power on the Panel and Computer

Main AC power to the panel coming through two MCBs first one at the main distribution

panel and second one inside the control panel. Computer has separate power supply point.

3.2 Log on to the computer. And SCADA system suppose start automatically in the computer.

If not double click (or select and press enter) to start the SCADA.

3.3 Press System start button if the system starting is successful System ready indicator will

activate. If not check the SCADA it will give a error massage. Check the status of emergency

button and DC MCB inside the panel.

3.4 Load/Create/Edit Recipe

3.5 Check Aggregate weighing settings and cement Weighing settings.

3.6 Switch on the Mixer Motor

3.7 Switch on the Transfer Conveyor. Note : to start transfer conveyor mixer motor has to run.

3.8 Start the Water Pump and Air Compressor

3.9 Wait some time for pressurize the pneumatic line.

3.10 Press Cycle start button.

3.11 If there were any errors in last cycle SCADA will prompt to clear them.

SCADA

This windows based SCADA system will control all the functions of system and following Chapters

describes the each function in detail.

SCADA

This is a quick reference guide for the SCADA (Visualization) for this system normal computer mouse

will be the pointing device and normal computer key board will use for character inputs.

Navigation Buttons

All the parameter windows and dialog boxes can access using the navigation buttons in bottom of

the screen. Single Left Click on any of these buttons needed to activate corresponding window. An

“EXIT” button will be use in all the windows to close the window.

Cement Silo – Load Window

SILO 01 BALANCE:

Current Balance of cement quantity in silo 01 in kilograms.

SILO 02 BALANCE:


SILO 01 (ADD QTY):

Adding quantity of cement to the silo 01 in kilograms. This quantity will add to ”SILO 01 BALANCE”

after pressing the “CONFIRM” button.

SILO 02 (ADD QTY):

Adding quantity of cement to the silo 02 in kilograms. This quantity will add to ”SILO 02 BALANCE”

after pressing the “CONFIRM” button.

Cement Silo – Unload Window

SILO 01 BALANCE:


SILO 02 BALANCE:


SILO 01 (SUB QTY):

Subtracting quantity of cement from the silo 01 in kilograms. This quantity will Subtract from ”SILO

01 BALANCE” after pressing the “CONFIRM” button.

SILO 02 (SUB QTY):

Subtracting quantity of cement from the silo 02 in kilograms. This quantity will Subtract from ”SILO

02 BALANCE” after pressing the “CONFIRM” button.

Measurement Parameter Window

There are three important parameters has to adjust using this window.

1. Free fall compensation:

Free fall compensation automatically corrects the free fall weight error while closing the

gate. Further explaining this parameter,

That means gate will start to close while some quantity of material remaining to fall from material

hopper.

Recipes – Window:

Select recipe:

The list box on left side will show all the active recipes on the system. With a single left click on any

of the recipe name will load the relevant data bind with that recipe name. The same method has to

use for switch among recipes.

Delete recipe:

User can delete any of unnecessary recipes in the system. Even user delete the recipe it will still

remain on the database for later report generation processes.

First of all user has to select the recipe and then user has to press delete Button. System will ask for

confirmation for this operation from user for avoids accidental recipe deletions.

Edit recipe:

This button facilitates for change any value in existing recipe on the system. As step one user has to

select the recipe and then user has to press “EDIT” Button. Then text fields will be enabling for edit

operation. After making all the changes user has to press the “SAVE” button for save changes to the

database.

Add new recipe:

When introducing new recipe to system user has to click on this button. It will open a new recipe will

set of empty fields. User has to put all the values to the recipe and click on save button for save the

recipe on system. After saving the recipe user can select that recipe using recipe selection list box.

Load to PLC:

The main function of recipe window is to load recipes from the data base and transfer same data

into PLC memory for operation. After making any change to recipe in recipe window user has to

press this button for transfer recipe.

Step 01: User has to select the recipe using recipe selection list box

Step 02: Verify data in selected recipe.

Step 03: Press “Load to PLC ” button.

Machine Parameter window

This window will facilitate to change any time interval parameter needed to change on going

operation.

Step 01: User has to press “READ” button for load current values from PLC

Step 02: Values has to enter in x100ms units. Enter all the parameters needed to change

Step 03: Press “WRITE” button for load values into PLC.

Note: Changes made to these parameters are not permanent and will be reset to default (typical)

values while restarting the PLC.

Any time user can close the window by pressing EXIT button.

CALIBRATION

Calibration designates a procedure to adjust weighing module so that it indicates correct reading

corresponding to the actual weight placed on the load cell. That is, Weighing Module must be

properly adjusted to indicate 100 kg when an actual load (Weight) of 100 kg is placed on the load cell

(sensing device). This process is called an actual loading calibration.

ZERO Calibration:

Gross weight should be shown in the text box in the window. And all the excess weights on the belt

should remove from the belt. After clear everything user has to press on “START” button for start

calibration process. After the ZERO calibration process gross weight should be “000” zero cleared. If

the value is wrong the Please perform the zero calibration again.

SPAN Calibration:

In this procedure, a known test load is placed on the cell to adjust the meter to indicate the desired

reading.

1. Place a Weight with exactly the same value as defined in Balance weight value on the load

cell. (Heavier than 50% Capacity load is recommended for better linearity.)

2. Check the load cell is free from undesired extra loading: extra foreign object on the weighing

plate, or contact with peripheral object.

3. Type the Calibration Weight value in the text box and press “WRITE” button.

4. Press start button to start the calibration process.

5. After the calibration gross weight should be same as calibration weight.

Remote Assistance:

User can enable remote assistance using this button. Active internet connection will be required in

this operation. User has to provide User ID and Password given by the system to the remote party to

get remote assistance.

4 Control panel part list

PART NO DESC QTY

CJ1M-CPU11 PLC CPU 1

CJ1W-ID211 INPUT UNIT 1

CJ1W-IDP01 HIGHSPEED INPUT UNIT 1

CJ1W-OC211 OUTPUT UNIT 2

CJ1W-F159 WEIGHNG MODULE 2

MY2IN 24VDC OMRON RELAY 34

PYF08AE RELAY BASE 32

S8JX-G10024CD DC POWER SUPPLY 1

A22S-2M-10 SELECTOR SWITCH 1

A165-TRM-2 PUSH BUTTON 1

A165-TGM-2 PUSH BUTTON 1

A22E-S-11 EMAGENCY SWITCH 1

1400

700 450

1000

1030

30

170

202.24

250

200

170

80B

C

D

1

A

321 4

B

A

5 6

5A .58A

M4-00 "+EXC" M5-00 "+EXC" M0-00 CIO 00.00 M1-00 CIO 01.00 M2-00 CIO 02.00 M3-00 CIO 03.00

M4-01 "+S" M5-01 "+S" M0-01 CIO 00.01 M1-01 CIO 01.01 M2-01 CIO 02.01 M3-01 CIO 03.01

M4-02 "-EXC" M5-02 "-EXC" M0-02 CIO 00.02 M1-02 CIO 01.02 M2-02 CIO 02.02 M3-02 CIO 03.02

M4-03 "-S" M5-03 "-S" M0-03 CIO 00.03 M1-03 CIO 01.03 M2-03 CIO 02.03 M3-03 CIO 03.03

M4-04 "RSV" M5-04 "RSV" M0-04 CIO 00.04 M1-04 CIO 01.04 M2-04 CIO 02.04 M3-04 CIO 03.04



M4-07 "OUT1" M5-07 "OUT1" M0-07 CIO 00.07 M1-07 CIO 01.07 M2-07 CIO 02.07 M3-07 CIO 03.07

M4-08 "OUT1" M5-08 "OUT1" M0-08 CIO 00.08 M1-08 CIO 01.08 M2-08 CIO 02.08 M3-08 CIO 03.08

M4-09 "SHIELD" M5-09 "SHIELD" M0-09 CIO 00.09 M1-09 CIO 01.09 M2-09 CIO 02.09 M3-09 CIO 03.09

M4-10 "+SIG" M5-10 "+SIG" M0-10 CIO 00.10 M1-10 CIO 01.10 M2-10 CIO 02.10 M3-10 CIO 03.10

M4-11 "-SIG" M5-11 "-SIG" M0-11 CIO 00.11 M1-11 CIO 01.11 M2-11 CIO 02.11 M3-11 CIO 03.11





M4-16 "OUT2" M5-16 "OUT2"

QTY CURRENT CONSUMPTION

1 0.58

2 0.16

2 0.22

1 0.56

1 0.6

.08A0.56A 0.30A .11A .11A

RESULT 5A>2.12A

CONSUMP

TION

0.08A

IO TABLE DESIGN

.58+.16+.22+.56+.6

2.12

UNIT TYPE

CPU

INPUT UNIT

OUTPUT UNIT

WEIGHING UNIT - 1

WEIGHING UNIT - 2

CJ1

W-ID

21

1

MO

DU

LE-01

MO

DU

LE-02

MO

DU

LE-03

MO

DU

LE-04

MO

DU

LE-05

CJ1

M-C

PU

11

CJ1

W-P

A2

05

R

MO

DU

LE-00

CJ1

W-ID

21

1

CJ1

W-O

C2

11

CJ1

W-O

C2

11

CJ1

W-F1

59

CJ1

W-F1

59

IO LIST WITH TERMINAL NUMBERS

Input EX-I T-NO PLC-T Output EX-O T-NO PLC-T IndicatorAGGREGATE BINS

Gate 1 Opened Feedback Signal LS1 X00 M0-00 Gate 1 Open Command CR00 Y00 M2-00

Gate 2 Opened FeedbackSignal LS2 X01 M0-01 Gate 2 Open Command CR01 Y01 M2-01



Gate 5 Opened Feedback Signal LS5 X04 M0-04 Gate 5 Open Command CR04 Y04 M2-04

FOR MANUAL OPERATION

Gate 1 Manual Open

Gate 2 Manual Open

Gate 3 Manual Open

Gate 4 Manual Open

Gate 5 Manual Open

WEIGHING CONVEYOR

Running feedback K1 X05 M0-05 ON Command CR05 Y05 M2-05 SCADA

Motor Over loaded Signal K2 X06 M0-06


SCADA Conveyor Manual ON

MATERIAL TRANSFER CONVEYOR

Running Feedback K3 X07 M0-07

Motor Overloaded K4 X08 M0-08

Hardware controlled (ON COMMND) TSW1 Z00 ON Command CR23


Ex-IP

SCADA

EX-IP

EX-IP

SCADA

VIBRATORS CEMENT BIN

Vibrator 1 - ON Command CR06 Y06 M2-06

Vibrator 2 - ON Command CR07 Y07 M2-07


Vibrator 1 Manual ON/OFF

Vibrator 2 Manual ON/OFF

CEMENT FEEDING CONVEYOR

Screw Conveyor 1 Running feedback K5 X09 M0-09 Screw Conveyor 1 ON Command CR08 Y08 M2-08

Screw Conveyor 2 Running feedback K6 X10 M0-10 Screw Conveyor 2 ON Command CR09 Y09 M2-09


Screw Conveyor Manual 1

Screw Conveyor Manual 2

CEMENT WEIGHING BIN

Gate Opened feedback LS6 X11 M0-11 Gate Open Command CR10 Y10 M2-10

Gate Closed feedback LS7 X12 M0-12 Vibrator ON command CR11 Y11 M2-11


Gate Open/Close Manual Command

Vibrator On/Off

WATER PUMP

Water cut off valve CR12 Y12 M2-12 SCADA


EX-I(PB) Water Cut off Valve Manual ON PB01 X13 M0-13

CHEMICAL DISPENSER

ON Command CR13 Y13 M2-13 SCADA


EX-I(PB) DISPENSER Manual ENEBLE PB02 X14 M0-14

EX-IP

SCADA

EX-IP

SCADA

SCADA

SCADA

SCADA

SCADA

MIXER

Motor running feedback K7 X15 M0-15

Gate OPENED Half feedback LS8 X16 M1-00 CR14 Y14 M2-14

Gate OPENED Full feedback LS9 X17 M1-01 Gate OPEN Full Command CR15 Y15 M2-15

Gate CLOSED feedback LS10 X18 M1-02 Gate CLOSE Command CR16 Y16 M3-00

Motor Overloaded Signal K8 X19 M1-03 Vibrator ON Command CR17 Y17 M3-01


NOT CTRL Motor ON Command TSW2 Z01 ON Command CR24

Gate Full OPEN Command

Gate Half OPEN Command

Gate Close Command

Vibrator ON Command

CEMENT MIXER FEEDING CONVEYOR

Separate system


HYDROULIC PUMP

Running feedback K9 X20 M1-04 Same Mixer gate open signal CR18 Y18 M3-02 SCADA

Overloaded Signal K10 X21 M1-05


NOT CRL Hydraulic Pump Manual ON

AIR COMPRESSOR

Separate system


EX-IP

SCADA

EX-IP

SCADA

SYSTEM

EX-IP(SS) Auto/Manual Input Signal SSW1 X22 M1-06

System Start Input Signal PB05 X23 M1-07

System Stop Input Signal PB06 X24 M1-08

EX-IP(ES) Emergency Switch Activated Signal EMG01 X25 M1-09

Pulse Input Water QI01 X26 M1-10

Pulse Input Chemical QI02 X27 M1-11

Next Cycle Call PB05 X28

HANDSHAKING SIGNALS

Machine Conveyor Running K11 System at automatic operation CR19 Y19 M3-03

DC POWER DETECT K12 Cement Mix ready CR20 Y20 M3-04

Mixer gate opened CR21 Y21 M3-05

Mixer gate closed CR22 Y22 M3-06

SCADA +

LIGHT

EX-IP(PB)

EX-IP

SPECIFICATION CORE NO RELAY TERMINAL NO MODULE NO

MIXER MOTOR - ON 1 CR24 TSW-2

CEMENT SCREW- 2 2 CR09 Y09 M2-09

CEMENT SCREW- 1 3 CR08 Y08 M2-08

TRANSFER CONVEYOR 4 CR23 TSW-1

WEIGHING CONVEYOR 5 CR05 Y05 M2-05

HYDRALIC PUMP - ON 6 CR18 Y18 M3-02

CON. HOPPER VIBRATOR 7 CR14 Y14 M2-14

MIXER GATE VIBRATOR - ON 8 CR17 Y17 M3-01

MIXER MOTOR RUNNING F.B - K7 9

K7(NORMALLY OPEN

CONTACT) X15 M0-15

DC - POWER 10

MATERIAL TRANSFER CONVEYOR RUNNING FB 11

K3(NORMALLY OPEN

CONTACT) X07 M0-07

DC - POWER 12

MIXER GATE OPEN COMMAND 13 CR15 Y15 M2-15

MIXER GATE CLOSE C0MMAND 14 CR16 Y16 M3-00

SPARE 15

SPARE 16

SPARE 17

MIXER OVERLOAD 18 K8 X19 M1-03

WEIGHING CONVEYOR OVER LOAD 19 K2 X06 M0-06

MATERIAL TRANSFER CONVEYOR OVER LOAD 20 K4 X08 M0-08

DC - POWER 21

AC INCOMMING 22

AC INCOMMING 23

24

24 CORE CABLE NO :1 ( CONNECTIONS)


WEIGHING CONVEYOR RUNNING FEED BACK SIGNAL1

K1 X05 M0-05

HYDRALIC PUMP MIXER GATE RUNNING FEED BACK SIGNAL2

K9 X20 M1-04

CEMENTW. GATE VIBRATOR ON COMMAND3

CR11 Y11 M2-11

CEMENT W.GATE MICROSWITCH (24 V SUPPLY)4

CEMENT W.GATE OPEN FEEDBACK SIGNAL5 MICRO SWITCH X11 M0-11

CEMENT W.GATE CLOSE FEEDBACK SIGNAL6 MICRO SWITCH X12 M0-12

CEMENT GATE OPEN COMMAND (PNEUMATIC VALVE ,24 V SUPPLY )7 CR10 Y10 M2-10

CEMENT SCREW MOTOR NO : 1 RUNNING FEEDBACK SIGNAL 8 K5 X09 M0-09

CEMENT SCREW MOTOR NO : 1 RUNNING FEEDBACK SIGNAL 9 K6 X10 M0-10

WATER SOLENOID VALVE10 CR12 Y12 M2-12

MIXER DOOR SAFTEY SWITCH11

12

13

14

15

16

17

18

19

20

230 V A.C SUPPLY COMMON21

230 V A.C SUPPLY COMMON22

23

24

24 CORE CABLE NO :2 ( CONNECTIONS)


COMM0N FOR ALL Pneumatic valve 1

AGG .PNEUMATIC VALVE No :1 2 CR00 Y00 M2-00





SPARE 7

SPARE 8

SPARE 9

SPARE 10

SPARE 11

Agg. Hopper no :1- Limit switch(LS-1) 12 LS1 X00 M0-00





COMMON FOR ALL LIMIT SWITCH 17

18

18 CORE CABLE ( CONNECTIONS)

SPECIFICATIONS CORE NO RELAY TERMINAL NO MODULE NO

MIXER GATE CLOSED LIMIT SWITCH - LS10 1 LS10 X18 M1-02

MIXER GATE HALF OPEN LIMIT SWITCH - LS8 2 LS8 X16 M1-00

MIXER GATE FULL OPEN LIMIT SWITCH - LS9 3 LS9 X17 M1-01

DC - POWER 4

8 CORE CABLE (CONNECTIONS)

LOAD CELL CABLE Module

RED EXIT +

BROWN SENS + NOT CONNECTED

BLACK EXIT -

BLUE SENS - NOT CONNECTED

GREEN SIG +

WHITE SIG -

Set value

Note : selector switch no :1 0 0

selector switch no :2 0 1

AGGREGATE LOAD CELL CONNECTIONS

LOAD CELL CABLE Module

RED EXIT +

BROWN SENS + NOT CONNECTED

BLACK SENS- NOT CONNECTED

BLUE EXIT-

GREEN SIG +

YELLOW SIG -

Set value

Note : selector switch no :1 0 0

selector switch no :2 0 1

CEMENT LOAD CELL CONNECTIONS

rino batching plant automation project

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