rs logix 5000 final report

PLC based Air Compressor Control Systems Project

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Project Report PLC based Air Compressor Control Systems Project Using

RSLogix 5000 and FactoryTalk View Site Edition

Akshay Gupta Dept. of Electrical & Electronics Engineering

Delhi Technological University New Delhi - 110042


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Project Report History/Approval

Revision History:

Rev. Date Comments

1.

01-Jul-15 Issued for Approval/Comment

Prepared by: Checked by: Approved by: Approval Notes and Exceptions

Prudent Solutions W.L.L PO Box: 11091

Building 1530, Road 736, Block 607 Kingdom of Bahrain


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ACKNOWLEDGEMENTS

I would like to thank Prudent solutions for giving me the opportunity for

doing this project and Mr. Anish Daniel for guiding me through it. All

references and software for the project were given to me for the duration

of the project by the company. I thank my seniors at prudent for all their

support.

Akshay Gupta


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TABLE OF CONTENTS Project Report History/Approval 2

1. INTRODUCTION 6

1.1. Acronyms & Abbreviations 6

1.2. Compressor Sequencing Control 6

2. SOFTWARE DESCRIPTION 7

2.1. RSLogix 5000 7

2.2. RS Linx Enterprise 8

2.3. Factory Talk View Site Edition 8

2.4. FactoryTalk View Studio 9

2.5. FactoryTalk View SE Client 9

3. HARDWARE DESCRIPTION 10

3.1. Allen Bradley ControlLogix System 10

3.2. PLC System Hardware Configuration 11

3.3. I/O Points 12

4. SYSTEM CONFIGURATION 13

4.1. Configuration of PLC programming software 13

1756-IF16A 17

1756-OB16D 18

1756-IB16D: 19

4.2. Communication Software Configuration 23

4.3. SCADA Graphic Configuration 25

4.4. Configuring alarms in SCADA 31

4.5. Configuring trends in SCADA 32

4.6. Configuring the Data Server in Site Edition 35

4.7. Setting up Data Logging 35

5. LOGIC DESCRIPTION 38

5.1. Automatic Control 38

5.2. Manual Control 39


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5.3. Safety Interlocks for Compressors 39

5.4. Analog Signal Filtering for Alarms & Trips 40

5.5. Transmitter Fault Detection 40

6. SCADA 42

6.1. Main Menu 43

6.2. Compressor K-T3-001A Train Screen 43

6.3. Compressor K-T3-001B Train Screen 43

6.4. Dry Air Receiver Trend Screen 44

6.5. System Utilities Screens 44

6.6. System Utilities Screens 45

6.7. Trend Screen 46

6.8. Alarm/Event Summary Screen 47

7. Appendix A – SCADA Screenshots 48

8. Appendix B - Alarm/Event Listing 57

9. Appendix C - Ladder Logic Code 59


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1. INTRODUCTION

This project aims at the automation of an Instrument Air Compressor using a

PLC based Control System. It involves the use of several different softwares

and procedures, each of which has been described in detail in this report.

1.1. Acronyms & Abbreviations

A-B Allen-Bradley ACD AutoCAD File AI Analog Input DAR Dry Air Receiver DI Digital Input DO Digital Output FDS Functional Design Specification H/W Hardware I/O Input and/or Output IACCS Instrument Air Compressor Control System IAC Instrument Air Compressor LCP Local Control Panel MCB Miniature Circuit Breaker MSP Motor Starter Panel PC Personal Computer PLC Programmable Logic Controller PSL Prudent Solutions WLL PS Power Supply RA Rockwell Automation S/W Software

1.2. Compressor Sequencing Control

Compressor sequencing control of both the IAC Train’s “A” & “B” is performed

by Allen Bradley Programmable Logic Controller. The control system has been

designed to perform continuous unattended operation all around the year. The

automatic sequencing program ensures that the pressure in the instrument air

header is maintained at optimum levels. Although primarily designed for

autonomous operation, the control system is provided with utilities for manual

control of equipment as and when required for routine maintenance and

startup.


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2. SOFTWARE DESCRIPTION

The softwares used for this project are as follows:

1. RSLogix 5000 (PLC Programming Software)

2. RS Linx Enterprise (Communication Software)

3. Factory Talk View Site Edition (SCADA software)

4. Factory Talk View Studio

5. Factory Talk View SE Client

The detailed description of the above software has been explained below.

2.1. RSLogix 5000

RSLogix 5000 Enterprise Series software is an IEC 61131-3 compliant software

package that offers relay ladder, structured text, function block diagram, and

sequential function chart editors for one to develop application programs. It

allows one to create their instructions by encapsulating a section of logic in any

programming language into an Add-On Instruction.

RSLogix 5000 programming package is compatible with programs created with

Rockwell Software DOS-based programming packages for the SoftLogix 58xx

Virtual Backplane and MicroLogix families of processors.

In addition, RSLogix 5000 benefits include:

Scalable and flexible solutions - Use modular code to simplify your

application

Efficient project design- Write code, organize it, test it, and duplicate it

Effective content management - Create content, store it, share it, and

reuse it

Quicker downtime recovery - Logically find what you need to quickly

troubleshoot code

Collaborative engineering - Enable multiple people to code, then

compare and merge

Support for more complex motion systems - Provide multiple update

rates


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2.2. RS Linx Enterprise

RSLinx Enterprise provides unparalleled connectivity between FactoryTalk

products and Rockwell Automation networks and controllers. RSLinx Enterprise

is optimized for Logix 5000 controllers. RSLinx Enterprise is the data server for

FactoryTalk View SE, FactoryTalk View ME, FactoryTalk Transaction Manager,

FactoryTalk Historian and FactoryTalk Metrics applications. It also provides

connectivity for FactoryTalk Alarms and Events and PanelView Plus and

VersaView hardware platforms.

RSLinx Enterprise is a FactoryTalk Live Data server and FactoryTalk Alarms and

Events server. RSLinx Enterprise configurations, which you create and modify

using the Communication Setup editor, are used by your applications to

communicate with devices (such as controllers and I/O scanners) on the plant

floor. This enables you to see values, such as sensor readings and other

controller data from your plant floor devices, on your desktop computer or

dedicated PanelView Plus terminal.

An RSLinx Enterprise configuration consists of:

A list of communication devices and their settings.

Device drivers and their associated properties.

A list of potential target devices

Shortcuts. A shortcut is a name that stands for the device you want to

connect to and the data that device contains. The communication path

associated with the shortcut tells the application where to find that data.

2.3. Factory Talk View Site Edition

FactoryTalk® View Site Edition (SE) is a supervisory-level HMI software for

monitoring and controlling distributed-server/multi-user applications. It

provides a comprehensive and accurate picture of operations, meeting the

demands of multiple stakeholders including engineering, maintenance,

operations, and production Information Technology (IT). Factory Talk View Site

Edition provides graphics, run-time user management, language switching and

faster commissioning time through a common development environment.


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2.4. FactoryTalk View Studio

FactoryTalk View Studio is configuration software for developing and testing

FactoryTalk View SE applications. FactoryTalk View Studio contains editors for

creating complete applications, and includes client and server software for

testing the applications you create. Use the editors to create applications that

are as simple or as complex as you need.

2.5. FactoryTalk View SE Client

FactoryTalk View SE Client is a complete runtime operating environment for

viewing and interacting with FactoryTalk View SE local and network

applications. To set up a FactoryTalk View SE Client, you need to create a

configuration file using the FactoryTalk View SE Client wizard. The HMI Server

does not have to be running when you configure a FactoryTalk View SE Client.

With the FactoryTalk View SE Client you can:

Load, view, and interact with multiple graphic displays at a time from

multiple servers

Perform alarm management

View real-time and historical trends

Adjust set points

Start and stop components on any server

Provide a secure operator environment


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3. HARDWARE DESCRIPTION

The primary elements of the system comprise of:

1. Allen Bradley ControlLogix 1756-L61 Controller

2. EtherNet/IP Network Communication Module

3.1. Allen Bradley ControlLogix System

Slot No. Modules

0 ControlLogix 1756-L61 Processor 1 EtherNet/IP Network Communication Module

1. 1756-L61 Controller

Two lines of standard ControlLogix controllers are now available. These

controllers are identified as 1756-L6x controllers and 1756-L7x controllers

according to abbreviations of their full catalog numbers. In this project, we

have used the ControlLogix l756-L61 Controller. The key features of the 1756-

L6x controller are as follows:

Feature 1756-L61

Clock support and backup used for memory retention at power down

Battery

Communication ports (built-in) Serial

Connections, controller 250

Memory, nonvolatile CompactFlash card

Status display and status indicators Six status indicator

Unconnected buffer defaults 10 (40, max)

The Controller is used in the Remote RUN mode. It executes the ladder logic

programs in the computer, updating the programs' data tables, allowing one to

approximate what is going to happen when one connects the real physical


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components to it. The rungs in the program read inputs from and write

outputs to the data table which is stored offline with the ladder logic project.

The offline data table is also active during the RUN mode.

The Controller has many methods for scanning the ladder logic. It can scan the

ladder logic continuously, one program scan at a time, or rung-by-rung. One

can also select a specific block of rungs to run. By selecting a block of rungs,

one is able to isolate that section of the program for testing purposes.

Naturally, all of the available scan modes are selectable while a block is

defined.

2. 1756-ENBT Module

EtherNet/IP networks are communication networks that offer a

comprehensive suite of messages and services for many automation

applications. These are examples of applications that use EtherNet/IP

networks:

i. Real Time Control

ii. Time Synchronization

iii. Motion

This open network standard uses off-the-shelf Ethernet communication

products to support real-time I/O messaging, information exchange, and

general messaging.

EtherNet/IP networks also support CIP Safety, making the simultaneous

transmission of safety and standard control data and diagnostics information

over a common network possible.

3.2. PLC System Hardware Configuration

Processor Type : 1756-L61

PLC I/O Processing Capability : 128,000 digital and 4,000 analog

PLC I/O usage for this application: 32 Digital / 16 Analog

Environment : 0-60oC, 95% R.H. (non-condensing)


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3.3. I/O Points

IO points configured for this application will as below,

16 Point 10V-31.2VDC,Electronically Fused Output (Model

No.1756-OB16E)

16 Channel Non-Isolated Voltage/Current Analog Input (Float

Data. Single ended mode)(Model No.1756-IF16)

16 Point 10V-31.2V DC Input, ( Model No.1756-IB16)


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4. SYSTEM CONFIGURATION

System engineering activities for each IACCS panel will encompass of:

1. Configuration of PLC programming software.

2. RS Linx Enterprise configuration

3. Configuration of Graphics for SCADA.

4. Configuration of Alarms.

5. Configuration of trends in SCADA

6. OPC server configuration in SCADA.

4.1. Configuration of PLC programming software

CONTROLLER PROPERTIES


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I/O CONFIGURATION AND I/O CARDS USED

The only rack used is the 1756-A7 7-slot rack of which 5 slots are used. The I/O

cards used are:

Slot I/O Card Used

2 16-Point 10V-31.V Analog Input (1756-IF16)

3 16 Point 10V-31.2V Electronically Fused Output (1756-OB16D)

4 16-Point 10V-31.V DC Input (1756-IB16D)

New I/O Modules were added as shown:


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From the above list, the desired I/O module can be selected and added into the program.


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The following is a picture of the Allen Bradley Chassis with the corresponding

modules installed in slots 0-4.

Various Electronic Keying options were available to the I/O modules. Electronic

Keying is a feature that reduces the possibility that you use the wrong device in

a control system. When the wrong device is used, unexpected system behavior

can occur.

The Electronic Keying automatically compares the expected device, as defined

in your project, to the installed device. If keying fails, the controller does not

establish a connection to the device and a fault occurs on the device.


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For each device in the project, the user-selected keying option determines if

and how an Electronic Keying check is performed. Three options are available:

Compatible Module: Compatible Module indicates that the device

determines whether to accept or reject communication.

Disable Keying: Disable Keying indicates the keying attributes are not

considered when attempting to communicate with a device

Exact Match: Exact Match indicates that all keying attributes of the

device that is defined in the project must match the attributes of the

installed device to establish communication.

I/O MODULE SPECIFICATIONS

1756-IF16A

It consists 16 Non-Isolated Voltage/Current Analog Input Points. Its input range

lies between 0-20mA. The card was installed in slot 2. The Requested Packet

Interval was set at 100 ms. The Card was given the name AI_01.


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Electronic Keying : Compatible Keying

1756-OB16D

The 1756-OB16E consists of 16 electronically fused output points. The

operating range lies between 19.2V-31.2V. The card was installed in slot 3. The

Card was given the name DO_01.


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Electronic Keying : Compatible Keying

1756-IB16D:

1756-IB16 consists of 16 individually isolated inputs. The operating voltage

range lies between 10 and 30V. Name given to this card was "DI_01" occupying

slot 4 of the Controller chassis. Change of state is allowed in both on->off and

vice versa.


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Electronic Keying : Compatible Keying ROUTINE DESCRIPTIONS:

MAIN ROUTINE The MAIN ladder is from where the execution of code begins. It contains jump to subroutine instructions which allow the compiler to scan through all the other subroutines.


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COMPRESSORA ROUTINE The COMPRESSOR_A ladder contains the execution ladder logic for

Compressor A. After setting the Compressor on duty/standby mode, there is

an option of setting the Compressor on automatic/manual. Once the choices

are made the Compressor motor is activated. A timer has been used to give a 5

second delay following which the after cooler motor begins operating. There is

an adder-timer combination that simulates the rate at which pressure loads

into the dry air receiver. Once the pressure in (tank) reaches the unload set

point (varies for duty and standby), the motor stays ON and the loading and

unloading begins. Only after pressure drops below load set point does loading

resume again. The no-load timer is introduced to switch off the motors if they

remain idle for an extended period of time. The logic for switching of the

system is such that when either the off button is pressed/no load timer

reaches its done value, after appropriate delays the system switches off.

COMPRESSOR B ROUTINE The COMPRESSOR B ladder contains the execution ladder logic for Compressor

B. After setting the Compressor on duty/standby mode, there is also the option

of setting the Compressor on automatic/manual. Once the choices are made

the Compressor motor is activated. A timer has been used to give a 5 second

delay following which the after cooler motor begins operating. There is an

adder-timer combination that simulates the rate at which pressure loads into

the dry air receiver. Once the pressure in (tank) reaches the unload set point

(varies for duty and standby), the motor stays ON and the loading and

unloading process begins. Only after pressure drops below load set point does

loading resume again. The no-load timer is introduced to switch off the motors

if they remain idle for an extended period of time. The logic for switching OFF

the system is such that when either the OFF button is pressed/no load timer

reaches its done value, after appropriate delays the system switches off.

UNLOADING_PROCESS ROUTINE

The UNLOADING_PROCESS Ladder consists of a subtractor-timer combination

that simulates the rate at which pressure unloads from the dry air receiver.


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CLOCK_ A ROUTINE

The CLOCK A Ladder is used to time the operation of the system. It also

contains the ladder logic to limit the starting of Compressor A to 3 times per

hour.

CLOCK _B ROUTINE

The CLOCK B Ladder is used to time the operation of the system. It also

contains the ladder logic to limit the starting of Compressor B to 3 times per

hour.

INPUT _MAPPING ROUTINE

The Input mapping ladder maps the feedback input values to binary registers

of the PLC for operation.

OUTPUT_MAPPING ROUTINE

OUTPUT _MAPPING ladder maps the feedback input values to binary registers

of the PLC for operation

ANALOG_INPUT_SCALING ROUTINE

ANALOG_MAP ladder scales the feedback analog input values for operation of

the PLC. In this routine, the inputs from the PLC are tested to ensure that they

are within the suitable range. If within the range, the inputs are then scaled

and stored into the Binary Data file. If not within the range, the corresponding

Alarm is triggered.

Alarms A ROUTINE

ALARMS A Ladder contains the ladder logic to trigger various alarms during the

operation of Compressor A.

Alarms B ROUTINE

ALARMS B Ladder contains the ladder logic to trigger various alarms during the

operation of Compressor B.


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MISC _FAULT ROUTINE

MISC FAULT Ladder contains the ladder logic to trigger the Common Transmitter Fault alarms of Compressors A and B.

4.2. Communication Software Configuration

CONFIGURATION OF DRIVER IN RSLINX CLASSIC:

i. Open RSLinx Classic by clicking Start > Programs >Rockwell

Software>RSLinx>RSLinx.

ii. In RSLinx Classic, click Communications > Configure Drivers. This opens

the Configure Drivers window.

iii. In the Configure Drivers window, select the driver you need to use based

on the physical connection to the processor.

iv. Click Add New to add the driver to the Configured Drivers list.

v. RSLinx Classic asks you to name the driver. RSLinx Classic uses this name

to refer to the driver .Click OK.

vi. The window that appears next depends on the driver that has been

selected .This window is where one can configure the driver. Configure

the driver to match the physical connection to the processor.

vii. When one has finished configuring the driver, the driver appears in the

Configured Drivers list of the Configure Drivers window. Click Close.


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viii. You need to make sure the communications driver you configured is

working properly. To do this, use the RSWho function in RSLinx Classic.

This function shows what processors and other communications devices

are available through the driver. To display an RSWho window, click

Communications>RSWho

ix. In the RS Who tree, open the driver you configured. You should see the

processor to which you want to connect. If the processor is seen, the

driver has been configured correctly and one can proceed to the next

step. If the processor cannot be seen, the driver is not configured

correctly (or some other communication problem is preventing from

accessing the processor). Correct the problem before proceeding.

CONFIGURING SYSTEM COMMUNICATIONS

x. In Factory Talk View (site edition) go to RSLinx Enterprise>

Communication Setup

xi. Add new and select L-61 driver from the left.


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4.3. SCADA Graphic Configuration

There are 9 graphic displays. They are as shown below:


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i. MAIN

The main screen has go-to push buttons that help navigate to the different graphic displays.


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ii. COMPRESSOR-A

The above figure shows the graphics on the SCADA screen for Compressor A. The tanks, air-oil-separator, wet air receiver,

dry air receiver etc. are all obtained from the symbol factory. The timers and indicator panels are all numeric displays. The

displays on the Mode Selection and Manual Control panels are maintained push buttons.


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iii. COMPRESSOR-B

The above figure shows the graphics on the SCADA screen for Compressor B. The tanks, air-oil-separator, wet-air-receiver,

dry air receiver etc. are all obtained from the symbol factory. The timers and indicator panels are all numeric displays. The

displays on the Mode Selection and Manual Control panels are maintained push buttons.


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iv. SYSTEM UTILITIES1

The system utilities – 1 panel provides a means to setup the set-points from SCADA during operation. The panels are

numeric input enable.


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v. SYSTEM UTILITIES2

The system utilities provide a means to oversee operation from SCADA. The panels are numeric input enable. The

operator may CLEAR any of these values should he/she wish to.


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4.4. Configuring alarms in SCADA

vi. ALARMS

Any alarms that have been triggered during operation shall be shown here. The active and unacknowledged alarms blink

and have white background and red writing. The active and acknowledged do not blink; have a white background and

purple writing. Options have been provided to simultaneously SILENCE/ACKNOWLEDGE ALL alarms.


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4.5. Configuring trends in SCADA

vii. TRENDS A

This screen shall display trends of the feedback analog inputs (indicator) for Compressor A. The panels on the right are

numeric displays which show the numeric value of the pressure indicated on the trends graph of Compressor A.


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viii. TRENDS B

This screen shall display trends of the feedback analog inputs (indicator) for Compressor B. The panels on the right are

numeric displays which show the numeric value of the pressure indicated on the trends graph of Compressor B.


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ix. DRY AIR RECEIVER TRENDS:

This screen shall display a continuous graph of the pressure in the Dry Air Receiver. The panel on the right is a numeric

display which shows the numeric value of the pressure indicated on the trends graph of the Dry Air Receiver


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4.6. Configuring the Data Server in Site Edition

At the name of the project (Air_Comp), right click to get the option of new OPC

data server and set the server as Rockwell Automation Device Server (RSLinx

Enterprise). When setting the tags for graphics/panels/indicators, choose from

the appropriate project.

4.7. Setting up Data Logging

To record the values displayed in trends, data logging is used. Right click on the

option in the explorer to start a new data log used for the entire project. Here

datalog1 is the data log used for the entire program.

Once the data log model is opened, we can set the maximum number of data

points to 300,000.The tags can be set in the Tags in Model option. This will let

us store values that are displayed in various trends.


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5. LOGIC DESCRIPTION

Each Compressor has Auto/Manual and Duty/Standby Selector buttons.

The Compressor can be run either in Auto or Manual mode depending on the

Auto/Manual/Off selector switch position. In either Auto or Manual mode, the

Compressor can be run in Duty or Standby mode depending on the selection of

the Duty/Standby Selector Switch. In either Auto or Manual mode, all safety

interlocks are active.

The Duty/Standby selector switch will assign different load/unload set point

ranges to each Compressor as indicated in table below. The ranges are

applicable in both Auto & Manual modes.

Switch Positions Load Unload

Duty 6.6 barg 8.3 barg

Standby 5.9 barg 6.9 barg

5.1. Automatic Control

There will be two Compressors called Train “A” and “B”. The purpose of

Duty/Standby selector switch is also to assign set point ranges to the

Compressors as indicated in table above. When the Instrument Air demand is

within the capacity of one Compressor, the Compressor selected on Duty will

be running and loading/unloading at its pre-set set points.When I/A demand is

increased beyond the capacity of the Duty Compressor and further DAR

pressure is dropped below Standby Compressor load set point, the Standby

Compressor will be started (if all interlocks have been established) beginning

to load/unload at the Standby set points.

When a Compressor is started, both the Compressor motor and the after

cooler motor will start simultaneously. When the Compressor motor reaches

its normal operating speed (10 seconds), the Compressor is ready to

load/unload at that time.


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For both Compressors (Duty & Standby), the Compressor motor and the after

cooler motor are stopped automatically when the I/A demand is reduced and

the Compressor is no longer required. This is achieved by the “NO LOAD”

timer, which measures the period for which the Compressor is idle. Each time

the individual Compressor unload set point is reached, the Compressor

unloads and the “NO LOAD" timer starts. If the timer pre-set period expires

and the relevant Compressor was not required to load, then that Compressor

will be stopped. The “NO LOAD” timer is initially set to 10 minutes (adjustable

through Operator Display) for both modes (Duty/Standby).

During the initial start or any other time, when the I/A pressure in the DAR is

below the Duty Compressor load set point, the Duty Compressor will start

automatically and will establish the pressure in the air receiver.

5.2. Manual Control

In Manual mode the ““NO LOAD”” timer is bypassed and the Compressor is

started and stopped only when the appropriate start / stop pushbutton

(Start/Stop PB’s will be enabled in manual mode) is operated. The

loading/unloading sequence is same as described above in Automatic control.

Same as in case of Auto mode, in Manual mode any stop created either by trip

signal or by pressing the STOP push button, first the loading Compressor will

unload and after 10 seconds the Compressor motor will stop.

5.3. Safety Interlocks for Compressors

A number of safety interlocks have been provided in the IACCS. The interlocks

protect the mechanical rotating equipment from damage and also ensure that

process conditions remain within designed operating parameters. A

malfunction in a particular Compressor during operation will be quickly sensed

by the PLC system via dedicated instruments mounted on the Compressor skid

(TIT-022A/B & PIT-082A/B). In these cases the PLC will de-energize the

loading/unloading valve and switch OFF the Compressor to minimize damage

to any of the units.

The LCP will trip the MSP in case of any Over Load alarms from Compressor /

After Cooler Motors or any of following trip alarms


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T3-TAHH-022A/B, Compressor Element Outlet Temperature High

High

T3-PAHH-082A/B, Compressor Element Outlet Pressure High

High

T3-TAHH-024A/B, Compressor Element Discharge Temperature

High High

The Compressors can be restarted only if the Fault is cleared and Reset PB on

MSP is reset by Operator.

5.4. Analog Signal Filtering for Alarms & Trips

All actions (Alarms, Trip & Control) derived from analog signals are delayed by

2 seconds. For example, if an alarm is generated at the set point of 16 mA,

then the transmitter output must stay above 16 mA for 2 seconds before the

alarm is initiated.

5.5. Transmitter Fault Detection

All the transmitters connected to LCP will be monitored for over range and

under range. Transmitter Fault is detected by monitoring the transmitter

output signal against upscale (>20 mA for 4 sec) or downscale (<4 mA for 4

sec).

The following Transmitter Fault alarms are grouped on the PLC Alarm Display

Unit window as Train A Transmitter Fault and Train B Transmitter Fault.

Sl. No. Tag No. Description

01 T3_PDIT_089A Compressor K-T3-001A Air Intake Filter; Diff. Pressure

02 T3_PIT_082A Compressor K-T3-001A Element; Outlet Pressure

03 T3_TIT_022A Compressor K-T3-001A Element; Outlet Temperature

04 T3_ PIT_083A Compressor K-T3-001A; Discharge Pressure

05 T3_TIT_024A Compressor K-T3-001A; Discharge Temperature

06 T3_PDI_090A Coalescing Filter S-T3-002A/003A, Differential Pressure


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07 T3_PDI_091A Particulate/ Active Carbon Filter, Differential Pressure

08 T3_AIT_002A Train A Skid Outlet ; Moisture

09 T3_PDIT_089B Compressor K-T3-001B Air Intake Filter; Diff. Pressure

10 T3_PIT_082B Compressor K-T3-001B Element; Outlet Pressure

11 T3_TIT_022B Compressor K-T3-001B Element; Outlet Temperature

12 T3_PIT_083B Compressor K-T3-001B; Discharge Pressure

13 T3_TIT_024B Compressor K-T3-001B; Discharge Temperature

14 T3_PDI_090B Coalescing Filter S-T3-002B/003B, Differential Pressure

15 T3_PDI_091B Particulate/ Active Carbon Filter, Differential Pressure

16 T3_AIT_002B Train B Skid Outlet ; Moisture


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6. SCADA

A number of graphic screens have been configured for monitoring all the

Compressor Skids and Air Receiver equipment’s which are connected to the LCP

of the PLC

Configured screens include:

1. Main Menu (default screen)

2. Compressor K-T3-001A Train Screen

3. Compressor K-T3-001B Train Screen

4. Compressor K-T3-001A Trends Screen

5. Compressor K-T3-001B Trends Screen

6. Air Receiver Trends Screen

7. Alarm/Event Summary Screen

8. System Utilities - 1

9. System Utilities – 2


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6.1. Main Menu

This screen has been configured to automatically display on the SCADA screen

during any startup of the Panel View unit. This screen will contain buttons to

access all the other screens. The operator will be able to access a particular

screen by simply pointing on the button and touching the desired description

of screen he wishes to monitor.

The system will always default to this screen on boot-up.

Screen functionality : Monitoring only

Security access : Open to all

6.2. Compressor K-T3-001A Train Screen

The screen contains all major the equipment including Compressor, cooling

fan, oil cooler, wet air receiver and filters etc. The screen provides a basic

overview of the present status of the equipment and processes at site.

Dynamic objects include but are not limited to:

Motor Status (Green for running)

Pressure Transmitter Indications (with PLC derived alarms)

Temperature Transmitter Indications (with PLC derived alarms)



6.3. Compressor K-T3-001B Train Screen

The screen contains all major the equipment including Compressor, cooling

fan, oil cooler, wet air receiver and filters etc. The screen provides a basic

overview of the present status of the equipment and processes at site.

Dynamic objects include but are not limited to:

Motor Status (Green for running)

Pressure Transmitter Indications (with PLC derived alarms)


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Temperature Transmitter Indications (with PLC derived alarms)



6.4. Dry Air Receiver Trend Screen

This screen displays a continuous graph of the pressure in the Dry Air Receiver.

The panel on the right is a numeric display which shows the numeric value of

the pressure indicated on the trends graph of the Dry Air Receiver.

Dynamic objects include but not limited to:

Pressure Transmitter Indications



6.5. System Utilities Screens

This screen allows the operator to access a number of utilities associated with

the IACCS system including:

DEVICE MAINTENANCE

This screen can be used for maintenance personnel to monitor the total run

hour of Compressors and number of operations motors as a key for doing

routine maintenance to these equipment’s



PARAMETER SETUP

In addition, this screen can be used by Supervisor/Engineer to enter the key

values like set points for temperature or pressure if it is used. The screen will

display the following information once selection is made: -


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Load/ Unload Set points for duty/standby modes can be modified

through this utility screen.

“No Load Time” for Compressor auto stop can be modified.

Set point modification of Alarms and trips.

All the entries will be through popup touch Keyboard.



6.6. System Utilities Screens

This screen allows the operator to access a number of utilities associated with

the IACCS system including:

DEVICE MAINTENANCE

This screen can be used for maintenance personnel to monitor the total run

hour of Compressors and number of operations motors as a key for doing

routine maintenance to these equipment’s



PARAMETER SETUP

In addition, this screen can be used by Supervisor/Engineer to enter the key

values like set points for temperature or pressure if it is used. The screen will

display the following information once selection is made: -

Load/ Unload Set points for duty/standby modes can be modified

through this utility screen.

“No Load Time” for Compressor auto stop can be modified.

Set point modification of Alarms and trips.

All the entries will be through popup touch Keyboard.


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6.7. Trend Screen

This screen can be used by operator view real time trending of all important

analog transmitter values by selection of individual transmitters or by group

trend displays of similar types.



The following transmitter values are logged:

Sl. No. Tag Description

01 T3_PDIT_089A Compressor K-T3-001A Air Intake Filter, Diff. Pressure

02 T3_PIT_082A Compressor K-T3-001A Element, Outlet Pressure

03 T3_TIT_022A Compressor K-T3-001A Element, Outlet Temp.

04 T3_PIT_083A Compressor K-T3-001A, Discharge Pressure

05 T3_TIT_024A Compressor K-T3-001A, Discharge Temp.

06 T3_PDI_090A Coalescing Filter A, Differential Pressure

07 T3_PDI_091A Particulate/ Active Carbon Filter A, Diff Pressure

08 T3_AIT_002A Train A Skid Outlet, Moisture

09 T3_PDIT_089B Compressor K-T3-001B Air Intake Filter, Diff. Pressure

10 T3_PIT_082B Compressor K-T3-001B Element, Outet Pressure

11 T3_TIT_022B Compressor K-T3-001B Element, Outlet Temp.

12 T3_PIT_083B Compressor K-T3-001B, Discharge Pressure

13 T3_TIT_024B Compressor K-T3-001B, Discharge Temp.

14 T3_PDI_090B Coalescing Filter B, Differential Pressure

15 T3_PDI_091B Particulate/ Active Carbon Filter B, Diff Pressure

16 T3_AIT_002B Train B Skid Outlet, Moisture


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6.8. Alarm/Event Summary Screen

Alarms and events will be displayed on a dedicated alarm/event summary

screen. The summary can be accessed by hitting the “Alarm Summary” button

on the Main Menu. The screen will display alarms and events in chronological

order. Active unacknowledged alarms will be depicted in red while active

acknowledged alarms would be depicted in white. Events will be depicted in

green. Inactive, acknowledged alarms will be deleted from screen.



Note: Refer to appendix A for listing of Alarms and events.


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7. Appendix A – SCADA Screenshots


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8. Appendix B - Alarm/Event Listing

Serial No. Alarm description 1. DAR Pressure LOW

2. DAR Pressure HIGH

3. PDIT 089A UNDER Range

4. PIT082 UNDER Range

5. TIT 022A UNDER RANGE

6. PIT 83A UNDER RANGE

7. TIT 24A UNDER RANGE

8. MIT 002A UNDER RANGE

9. PDIT 090A UNDER RANGE

10. PDIT 091A UNDER RANGE

11. PIT 089B UNDER RANGE

12. PIT 082 UNDER RANGE

13. TIT 022B UNDER RANGE

14. PI T3 083B UNDER Range

15. TI T3 024B UNDER RANGE

16. MIT 002B UNDER RANGE

17. PDIT 090B UNDER RANGE

18. PDIT 091B UNDER RANGE

19. PDIT 089A Over Range

20. PIT082 Over Range

21. TIT 022A OVER RANGE

22. PIT 83A OVER RANGE

23. TIT 24A OVER RANGE

24. MIT 002A OVER RANGE

25. PDIT 090A OVER RANGE

26. PDIT 091A OVER RANGE

27. PIT 089B OVER RANGE

28. PIT 082 OVER RANGE

29. TIT 022B OVER RANGE

30. PI T3 083B Over Range

31. TI T3 024B OVER RANGE

32. MIT 002B OVER RANGE

33. PDIT 090B OVER RANGE

34. PDIT 091B OVER RANGE

35. PDIT-089A Xmitter Out of Range Alarm


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36. PIT-082A Xmitter Out of Range Alarm

37. TIT-022A Xmitter Out of Range Alarm

38. PIT_083A Xmitter Out of Range Alarm

39. TIT-024A Xmitter Out of Range Alarm

40. MIT-002A Xmitter Out of Range Alarm

41. PDIT_090A Xmitter Out of Range Alarm

42. PDIT_091A Xmitter Out of Range Alarm

43. PDIT-089B Xmitter Out of Range Alarm

44. PIT-082B Xmitter Out of Range Alarm

45. TIT-022B Xmitter Out of Range Alarm

46. PIT-083B Xmitter Out of Range Alarm

47. TIT_024B_FAULT

48. MIT 201B Xmitter Out of Range Alarm

49. PDIT 090B Xmitter OUT of Range Alarm


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9. Appendix C - Ladder Logic Code

The Ladder Logic Code for the Project has been given in: RSLogix 5000 Project Report: AIR_COMPRESSOR

rs logix 5000 final report

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