Professional Documents
Culture Documents
AUTOMATION PROJECT
CUSTOMER
COMPLETION DATE
10/19/2011
DEPARTMENT
Industrial Automation
DOCUMENT TITLE
DOCUMENT NO
PRJ-FJRC01-D02-V
Deira General Marketing : P.O. BOX 11370 : DUBAI UAE : TEL- 00971 4 2545777 : FAX 00971 4 2545559 : EMAIL: dgmsales@emirates.net.ae : WEB www.dgm-aws.com
1. OVERVIEW OF PLANT
18 20 52 16
21 19
17
14
15 8 13 10 11
MIXER 12 7 9 26
3 5 4 2 5 1 6
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
1.3
1.4
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
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
SYSTEM START
CONTROL POWER ON
EMEGENCY ENABLED
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.
Cycle Start
System Ready
AND
Normal Sequence
OPEN GATE 1
START SCREW 1
CLOSE GATE 1
STOP SCREW 1
GATE 1 CLOSE ERROR BIN2 FF.CPS REACHED STOP SCREW 2 CLOSE GATE 2
GATE 2 CLOSED
2.3
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. 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.
II.
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: Current Balance of cement quantity in silo 02 in kilograms. 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.
SILO 01 BALANCE: Current Balance of cement quantity in silo 01 in kilograms. SILO 02 BALANCE: Current Balance of cement quantity in silo 02 in kilograms. 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.
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.
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.
170
A A
202.24
30 1400
1030
700
450
250
200
80
170
1000
IO TABLE DESIGN
5A .58A M4-00 M4-01 M4-02 M4-03 M4-04 M4-05 M4-06 M4-07 M4-08 M4-09 M4-10 M4-11 M4-12 M4-13 M4-14 M4-15 M4-16 0.56A "+EXC" "+S" "-EXC" "-S" "RSV" "RSV" "RSV" "OUT1" "OUT1" "SHIELD" "+SIG" "-SIG" "RSV" "RSV" "RSV" "RSV" "OUT2" M5-00 M5-01 M5-02 M5-03 M5-04 M5-05 M5-06 M5-07 M5-08 M5-09 M5-10 M5-11 M5-12 M5-13 M5-14 M5-15 M5-16 0.30A "+EXC" "+S" "-EXC" "-S" "RSV" "RSV" "RSV" "OUT1" "OUT1" "SHIELD" "+SIG" "-SIG" "RSV" "RSV" "RSV" "RSV" "OUT2" M0-00 M0-01 M0-02 M0-03 M0-04 M0-05 M0-06 M0-07 M0-08 M0-09 M0-10 M0-11 M0-12 M0-13 M0-14 M0-15 0.08A CIO 00.00 CIO 00.01 CIO 00.02 CIO 00.03 CIO 00.04 CIO 00.05 CIO 00.06 CIO 00.07 CIO 00.08 CIO 00.09 CIO 00.10 CIO 00.11 CIO 00.12 CIO 00.13 CIO 00.14 CIO 00.15 M1-00 M1-01 M1-02 M1-03 M1-04 M1-05 M1-06 M1-07 M1-08 M1-09 M1-10 M1-11 M1-12 M1-13 M1-14 M1-15 .08A CIO 01.00 CIO 01.01 CIO 01.02 CIO 01.03 CIO 01.04 CIO 01.05 CIO 01.06 CIO 01.07 CIO 01.08 CIO 01.09 CIO 01.10 CIO 01.11 CIO 01.12 CIO 01.13 CIO 01.14 CIO 01.15 M2-00 M2-01 M2-02 M2-03 M2-04 M2-05 M2-06 M2-07 M2-08 M2-09 M2-10 M2-11 M2-12 M2-13 M2-14 M2-15 .11A CIO 02.00 CIO 02.01 CIO 02.02 CIO 02.03 CIO 02.04 CIO 02.05 CIO 02.06 CIO 02.07 CIO 02.08 CIO 02.09 CIO 02.10 CIO 02.11 CIO 02.12 CIO 02.13 CIO 02.14 CIO 02.15 M3-00 M3-01 M3-02 M3-03 M3-04 M3-05 M3-06 M3-07 M3-08 M3-09 M3-10 M3-11 M3-12 M3-13 M3-14 M3-15 .11A CIO 03.00 CIO 03.01 CIO 03.02 CIO 03.03 CIO 03.04 CIO 03.05 CIO 03.06 CIO 03.07 CIO 03.08 CIO 03.09 CIO 03.10 CIO 03.11 CIO 03.12 CIO 03.13 CIO 03.14 CIO 03.15 CJ1W-ID211 CJ1W-ID211 CJ1W-OC211 CJ1W-OC211 CJ1W-F159 CJ1W-F159
MODULE-01
MODULE-00
CJ1M-CPU11
MODULE-02
UNIT TYPE QTY CPU 1 INPUT UNIT 2 OUTPUT UNIT 2 WEIGHING UNIT - 1 1 WEIGHING UNIT - 2 1 CONSUMP TION RESULT
CJ1W-PA205R
MODULE-03
MODULE-04
MODULE-05
CURRENT CONSUMPTION 0.58 0.16 0.22 0.56 0.6 .58+.16+.22+.56+.6 2.12 5A>2.12A
EX-I
LS1 LS2 LS3 LS4 LS5
T-NO
X00 X01 X02 X03 X04
PLC-T Output
M0-00 M0-01 M0-02 M0-03 M0-04 Gate 1 Open Command Gate 2 Open Command Gate 3 Open Command Gate 4 Open Command Gate 5 Open Command
EX-O
CR00 CR01 CR02 CR03 CR04
T-NO PLC-T
Y00 Y01 Y02 Y03 Y04 M2-00 M2-01 M2-02 M2-03 M2-04
Indicator
Ex-IP
SCADA
SCADA
EX-IP
K1 K2
X05 X06
M0-05 M0-06
ON Command
CR05
Y05
M2-05
SCADA
SCADA
EX-IP
K3 K4 TSW1
VIBRATORS CEMENT BIN Vibrator 1 - ON Command Vibrator 2 - ON Command SCADA FOR MANUAL OPERATION Vibrator 1 Manual ON/OFF Vibrator 2 Manual ON/OFF CEMENT FEEDING CONVEYOR Screw Conveyor 1 Running feedback Screw Conveyor 2 Running feedback FOR MANUAL OPERATION Screw Conveyor Manual 1 Screw Conveyor Manual 2 CEMENT WEIGHING BIN Gate Opened feedback Gate Closed feedback FOR MANUAL OPERATION Gate Open/Close Manual Command Vibrator On/Off WATER PUMP Water cut off valve FOR MANUAL OPERATION EX-I(PB) Water Cut off Valve Manual ON CHEMICAL DISPENSER ON Command FOR MANUAL OPERATION EX-I(PB) DISPENSER Manual ENEBLE PB02 X14 M0-14 CR13 Y13 M2-13 SCADA CR12 Y12 M2-12 SCADA CR06 CR07 Y06 Y07 M2-06 M2-07 SCADA
EX-IP
K5 K6
X09 X10
M0-09 M0-10
CR08 CR09
Y08 Y09
M2-08 M2-09
SCADA
SCADA
EX-IP
LS6 LS7
X11 X12
M0-11 M0-12
CR10 CR11
Y10 Y11
M2-10 M2-11
SCADA
SCADA
PB01
X13
M0-13
EX-IP
MIXER Motor running feedback Gate OPENED Half feedback Gate OPENED Full feedback Gate CLOSED feedback Motor Overloaded Signal
SCADA
FOR MANUAL OPERATION NOT CTRL Motor ON Command Gate Full OPEN Command Gate Half OPEN Command SCADA Gate Close Command Vibrator ON Command CEMENT MIXER FEEDING CONVEYOR Separate system FOR MANUAL OPERATION
TSW2
Z01
ON Command
CR24
EX-IP
K9 K10
X20 X21
M1-04 M1-05
CR18
Y18
M3-02
SCADA
FOR MANUAL OPERATION NOT CRL Hydraulic Pump Manual ON AIR COMPRESSOR Separate system FOR MANUAL OPERATION
SYSTEM EX-IP(SS) Auto/Manual Input Signal System Start Input Signal EX-IP(PB) System Stop Input Signal EX-IP(ES) Emergency Switch Activated Signal Pulse Input Water EX-IP Pulse Input Chemical Next Cycle Call HANDSHAKING SIGNALS Machine Conveyor Running DC POWER DETECT
SSW1 X22 PB05 X23 PB06 X24 EMG01 X25 QI01 X26 QI02 X27 PB05 X28 K11 K12
System at automatic operation Cement Mix ready Mixer gate opened Mixer gate closed
SCADA + LIGHT
Module EXIT + SENS + EXIT SENS SIG + SIG NOT CONNECTED NOT CONNECTED
Note :
Set value 0 0
0 1
Note :
Set value 0 0
0 1