B.E.

PROJECT REPORT
(PART II)

ON

“PLC BASED COAL HANDLING SYSTEM”

Submitted by
Sagar Sanjay Bhalekar (B150452503)
Priyanka Ramchandra Ghodake (B150452522)
Tejal Dipak Kahane (B150452527)
Shweta Bhanudas Sonkamble (B150452560)

UNDER THE GUIDANCE OF

PROF. BALAJI BHURE (Internal Guide)

IN PARTIAL FULFILMENT OF DEGREE

B.E. (ELECTRICAL)
SAVITRIBAI PHULE PUNE UNIVERSITY
2018-2019

MARATHWADA MITRA MANDAL’S COLLEGEOF ENGINEERING,PUNE-52

DEPARTMENT OF ELECTRICAL ENGINEERING

MMCOE, Department of Electrical Engineering. Page 1

 PREFACE

Students, in the final year, take up a project in the field closely related to Electrical
Engineering. This project work is based on knowledge acquired by the student during
graduation and preferably should meet and contribute towards the needs of society. The
project aims to provide an opportunity of designing and building complete system based on
area where the student likes to acquire specialized skills. It gives an opportunity to the
students to learn how to manage projects in multidisciplinary environment and to make use of
modern engineering tools and techniques while executing their project work.

Evaluation of each project is done on the basis of nature of project, presentation skills and
team work exhibited by students, commitment to professional ethics, ability of the students to
answer questions raised by the evaluation committee members and quality of project report
and technical paper. The quality of project is also assessed in terms of consideration to factors
including environment, safety, cost, application, research etc.

Keeping this in mind, the course outcomes are prepared. Proper mapping is also done with
the program outcomes and program specific outcomes. This clearly states the goals for the
students for their overall skill development.

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MMCOE, Department of Electrical Engineering. Page 3
 Department of Electrical Engineering

Vision
Quality Education to create Competent Electrical
Engineering Professionals

Mission
▪ To provide excellent academic environment through
interactive teaching learning

▪ To impart value-based education via social connectivity

▪ To develop interdisciplinary skills by add-on activities

MMCOE, Department of Electrical Engineering. Page 4

 Department of
ELECTRICAL ENGINEERING

Program Educational Objectives (PEOs)

1. To impart core knowledge to identify, analyze and solve the electrical engineering problems.
2. To inculcate professional ethics and usage of modern tools to achieve sustainable carrier growth.
3. To enhance communication skills and leadership qualities with continuous self-development.

Program Outcomes (POs)

Engineering Graduates will be able to:

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals,
and an engineering specialization to the solution of complex engineering problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and
engineering sciences.
3. Development of solutions: Design solutions for complex engineering problems and design system
components or processes that meet the specified needs with appropriate consideration for the public
health and safety, and the cultural, societal, and environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research methods
including design of experiments, analysis and interpretation of data, and synthesis of the information to
provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modelling to complex engineering activities with an
understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal,
health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional
engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering solutions in
societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable
development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of
the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader in
diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the engineering
community and with society at large, such as, being able to comprehend and write effective reports and
design documentation, make effective presentations, and give and receive clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the engineering and
management principles and apply these to one's own work, as a member and leader in a team, to
manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in
independent and life-long learning in the broadest context of technological change.

Program Specific Outcomes (PSOs)

Electrical Engineering graduates will be able to:

1. Design, develop and test AC-AC, AC-DC and DC-DC converters, variable DC power supply by using
power electronics components to fulfil electrical engineering requirements.
2. Design and develop LT distribution and PLC control panel using suitable Switchgear, sensors, Push
buttons, Selector switches as per IEC standards and integrate it in smart automation.

MMCOE, Department of Electrical Engineering. Page 5

 A. Course Outcomes:

Statement
Course
Outcome
At the end of the course, a student will be able to:

403151.1 Review research literature related with the project title and apply the
knowledge of basic science and engineering fundamentals in solving complex
engineering problems by using appropriate hardware/software including
demonstration of working prototype/s

403151.2 Design solutions to solve complex engineering problems taking into

consideration the specific needs related with public health, safety, society,
culture and environment leading to sustainable development

403151.3 Apply appropriate techniques, resources and modern engineering tools during
the implementation of project, with understanding of the limitations

403151.4 Communicate, comprehend, and present effectively on complex engineering

activities during the implementation of the project work by application of
professional ethics

403151.5 Demonstrate knowledge and understanding of engineering and management

principles and function effectively as an individual and as a member or leader
of a diversified team

403151.6 Execute a multidisciplinary project leading to the ability of engagement in

lifelong learning and self-development

B. CO-PO/PSO Mapping:

PO PSO
Course
Outcome
1 2 3 4 5 6 7 8 9 10 11 12 1 2

403151.1 3 3 - - - - - - - - - - - -

403151.2 - - 3 2 - 3 3 - - - - - 2 2

403151.3 - - - - 3 - - - - - - - - 2

403151.4 - - - - - - - 3 - 3 - - - -

MMCOE, Department of Electrical Engineering. Page 6

403151.5 - - - - - - - - 3 - 3 - - -

403151.6 - - - - - - - - - - - 3 2 2

Level 1 1 1 1 1 1 1 1 1 1 1 1 1 1

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 MARATHAWADA MITRA MANDAL’S
COLLEGE OF ENGINEERING,
KARVENAGAR PUNE-52
Accredited with ‘A’ Grade by NAAC

CERTIFICATE
This is to certify that the project seminar report entitled

“PLC BASED COAL HANDLING SYSTEM”

Submitted by

Sagar Sanjay Bhalekar (B150452503)

Priyanka Ramchandra Ghodake (B150452522)
Tejal Dipak Kahane (B150452527)
Shweta Bhanudas Sonkamble (B150452560)

is a bonafide work carried out by them under the supervision of Prof.B.B.Bhure and it is
approved for the partial fulfilment of requirement of Savitribai Phule Pune University for
award of the degree of Bachelor of Engineering (Electrical).

This project seminar report has not been submitted earlier to any other Institute or University
for the award of any degree or diploma.

Project Guide Dr. V. N. Gohokar Dr. S. M. Deshpande Mr. Nitin Chaphekar

Electrical Department HOD Principal External Examiner

Date:

MMCOE, Department of Electrical Engineering. Page 8

 INDEX

1. Project Abstract………………………………………………………………..…..…....13
2. Scheme of Implementation of Project with Block Diagram………………….……....12
2.1. Block Diagram.............................................................................................................14
2.2. Project Structure..........................................................................................................14
2.3. Coal handling process.................................................................................................15
2.4. Features of better coal handling system.......................................................................15
2.5. Objectives....................................................................................................................15
2.6. Scope...........................................................................................................................15
2.7. Input/Output module..................................................................................................15
2.8. Hardware.....................................................................................................................16
2.9. PLC .............................................................................................................................17
2.10. Conveyor...................................................................................................................18
3. Software..............................................................................................................................20
3.1. Ladder programming....................................................................................................21
3.2. SCADA Screen.............................................................................................................24
4. Advantages..........................................................................................................................25
5. Literature Review ………………………………………………………………..……...27
5.1. Paper 1………………………………………………………………………...……...28
5.2. Paper 2…………………………………………………………………………...…...28
5.3. Paper 3………………………………………………………………………...……...29
5.4. Paper 4……………………………………………………………………………......29
5.5. Paper 5………………………………………………………………………….........30
5.6. IEEE Papers…………………………………………………………………........….31
6. Selection of Component and Estimation of Project Cost...............................................32
6.1. Components required………………………………………………………..….……33
6.2. Estimation of project cost…………………………………………………………....35
7. Technical Specification of System and Sub Components……………………..……....36
8. Testing of System Sub Components…………………………………………………....38
8.1. Observation table........................................................................................................40
9. Result and Conclusion…………………………………………………………………..41

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10. References……………………………………………………….……………………...43
10.1. Research papers and books………………………………..……………….............44
10.2. Websites…………………………………………………..……………………......45

LIST OF FIGURES

2.1. Block diagram………………………………….………………………………...….14

2.2. Project structure……………………………………………………..…….……..….14
2.7. Input Output Module………………………………………………………..…….....15
2.8. Hardware……………………………………………………………………….…....16
2.9.1. PLC block diagram………………………………………………………………...17
2.9.2. PLC………………………………………………………………………………..18
2.10. Conveyor…………………………………………………………………………..1.8
3.2. SCADA Screen...........................................................................................................24

8.a. Testing of relay channel ............................................................................................38

8.b. Interfacing of PLC with computer.............................................................................38
8.c.Testing of push buttons, indicating lamp, toggle switch and limit switch.................38
8.d. Testing of dc geared motor........................................................................................39

LIST OF TABLES

6.2. Estimation of Project cost…………………………………………………..…….…35

7. Technical Specification of System and Sub components…….…..…………...……....37
8.1.Observation Table……………………………………….……………………….......40

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 CHAPTER 1

Project Abstract

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 1. PROJECT ABSTRACT

Most of the old power plant sub-system controlled by electromechanical relay control
system. These systems are very difficult for maintenance & not having proper user interface.
By using hundreds of relays in series and/or parallel combination for particular tripping or
staring interlock is defined. Most of the control circuit uses 110VAC as control supply. If we
are using 110VAC as control supply then it is not required that any type of AC to DC
conversion. The most common control supply used for sequence control interlock panels is
50VDC which require battery arrangement. In order to fulfill reliability, constrain there
should stand by feeder &auto changeover of supply. In case of electromechanical relay logic
troubleshooting is very difficult. The programmable logic controller eliminates all
disadvantages of analog systems. PLC is the one of the suitable solution for thermal power
plant operating.

In thermal power plant the demand for higher reliability & efficiency is increasing. Power
plant requires continuous inspection & monitoring after regular intervals. There may be
chances of errors while measuring at various stages by human workers. In order to increase
reliability the automation is needed so that overall efficiency of power plant gets improved.

The automation is developed by using PLC &SCADA which reduces the errors caused by
human workers.PLC is programmable logic control. It is used for implementing various
functions such as sequencing, timing, counting, logic & arithmetic control through Analog
and Digital input output modules.

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 CHAPTER 2

Scheme of Implementation of Project with Block Diagram

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 2.1. Block Diagram

2.2. Project Structure

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2.3. Coal Handling Process
• Coal delivery
• Unloading
• Preparation of coal
• Transfer of coal
• Storage of coal
• Crushers

2.4. Features of better coal handling System

• It should have minimum maintenance.
• It should be simple.
• It should be reliable.
• It should supply coal continuously as per the demand of power plant.
• It should have minimum wear in running the equipment

2.5. Objectives
The objectives of this project are as follows:
• To make automation system using PLC.
• To save energy of a system.
• To avoid accidents.
• To monitor parameters of coal.
• To monitor parameters of conveyor belt.
• To reduce human efforts

2.6. Scope

This research work provides an efficient method for improving response of system.
Automation increases efficiency of system. Efficient system will yield best results.
Applying automation in application like coal crushing system is a best idea as coal crushing
system automates the coal crushing industry. Application of coal crushing system provides
optimal results. To show the effectiveness and efficiency of the algorithm, the HMI
implementation is studied.

2.7. Input / output module

Figure (a).Input module

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 Figure (b). Output module

The system uses ALLEN BRADLLEY PLC. According to the process and control
requirements, the input module includes input button, exit button, automatic manual switch
button, fault protection, variable signal, limit switches and so on. The output module includes
feed valve, pressure valve, anti-blocking valve, delivery valve, discharge valve, exhaust
valve, fault output and other switch instructions and corresponding indicator lights.

2.8. Hardware

a. Power Supply

This can be built into the PLC or be an external unit. Common voltage levels required by the
PLC (with and without the power supply) are 24Vdc, 120Vac, 220Vac.

b. CPU

(Central Processing Unit) - This is a computer where ladder logic is stored and processed.

c. I/O (Input/output)

MMCOE, Department of Electrical Engineering. Page 16

A number of input/output terminals must be provided so that the PLC can monitor the
process and initiate actions. It is Flexible and easy to maintain.

d. Indicating lamps

These indicate the status of the PLC including power on, program running, and a fault. These
are essential when diagnosing problems. The configuration of the PLC refers to the
packaging of the components.

e. Rack

A rack is often large (up to 18” by 30” by 10”) and can hold multiple cards. When necessary,
multiple racks can be connected together. These tend to be the highest cost, but also the most
flexible and easy to maintain.

2.9 PLC block Diagram

Figure. 2.9.1

Fig. 2.9.1 and Fig. 2.9.2 shows Programmable Logic Controller (PLC). It is a digital
computer used for the automation of various electro-mechanical processes in industries.
These controllers are specially designed to survive in harsh situations and shielded from heat,
cold, dust, and moisture etc. PLC consists of a microprocessor which is programmed using
the computer language.
The program is written on a computer and is downloaded to the PLC via cable. These
loaded programs are stored in non – volatile memory of the PLC.

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 Figure. 2.9.2

There are two types of contacts in PLC's and they are normally open and normally
closed switches. A normally open contact means the contact is on when pressed/closed, and a
normally closed contact is on when open/not pressed.
Contacts represent the states of real world inputs like sensors, switches, if the part is
present, empty, full, etc. PLC's also consist of coils, which are outputs like motors, pumps,
lights, timers, etc. The PLC examines inputs and turns coils on or off whenever it is needed.

2.10. Conveyor
This coal is transported up to the coal storage bunkers through conveyor belts. Coal is
then transported to the Crush house by conveyor belts where it is crushed to small pieces and
light dust is separated. The crushed coal is transported from crusher to thermal power plant
through conveyor belt and is used in boiler. The following types conveyors used for
transferring the coal are listed below.
• Screw conveyor
• Bucket conveyor
• Grab Bucket Conveyor
• Skip Hoists
• Flight Conveyor belt.
• Belt conveyor

Figure. 2.10.1

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 The initial cost of this coal carrying system is not high and power consumption is also
low as compared with another conveyors. The belt conveyors are successfully used on
inclination up to 20 to the horizontal. The load carrying capacity of the belt conveyors may
vary from 50 to 100 tonnes/hr and it can be easily transferred through 400 meters. It is not
suitable for short distances and greater heights.

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 CHAPTER 3

Software

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 3. Software required for PLC control system

Ladder logic- RS Logix 500 English

Rockwell Automation, Inc. (NYSE: ROK), is an American provider of industrial

automation and information products. Brands include Allen-Bradley and Rockwell Software.
Headquartered in Milwaukee, Wisconsin, Rockwell Automation employs over 22,000 people
and has customers in more than 80 countries worldwide. The Fortune 500 Company reported
$6.35 billion in sales in 2013.

3.1. Ladder programming

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MMCOE, Department of Electrical Engineering. Page 22
 Figure (a). ladder diagram

SCADA- WONDERWARE INTOUCH

Wonderware InTouch is award-winning HMI visualisation software that empowers

customers to achieve their quest for operational excellence. Let InTouch take you beyond
simplistic graphics to create meaningful content that will drive enterprise-wide operations
productivity and cost savings.
Supervisory control and data acquisition (SCADA) is a system of software and hardware
elements that allows industrial organizations to: ... Directly interact with devices such as
sensors, valves, pumps, motors, and more through human-machine interface (HMI) software.

MMCOE, Department of Electrical Engineering. Page 23

3.2 SCADA Screen

Figure 3.2 SCADA screen

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 CHAPTER 4

Advantages

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 4. ADVANTAGES

• By using PLC, the system becomes more reliable, efficient and increases the
productivity.

• Fault detection and clearing becomes easy.

• Another benefit of automation is the reduction in the number of hours worked on

average per week by worker.

• Increases the safety.

• Using SCADA (supervisory control and data acquisition) platforms for your building
automation system allows you to get exactly the features and capabilities you want
now and in the future as your needs grow.
• SCADA systems are powerful, robust and flexible. They can connect to and manage
thousands of sensors and record vast amounts of data. Reports can display whatever
you like and be viewed from anywhere. In addition, SCADA systems can perform
real data simulations.
• SCADA is robust:
Manufacturers, water treatment and other operations have been relying for decades on
SCADA systems to control their processes. In these environments, unplanned downtime 35
can be extremely disruptive and costly. This time-proven robustness makes SCADA 99
systems a good choice for building automation monitoring and control.
• Integratability:
Over the years, users have demanded that SCADA system developers enable
connectivity with the unlike systems and networks with their plants. This openness is
highly beneficial for building automation systems with the many diverse component
systems to be integrated.
• Flexibility:
SCADA systems are scalable and upgradeable. You can start small and grow. Or
implement a complete system from the start. SCADA technology will not hold you back.
• Reporting:
Which reports do you want where at what time? Want to see status on all your systems
from any web browser anywhere, even from your smart phone?With SCADA, you can do
it. As you can also, if you chose, enable control over remote connections, we advise well-
thought access and security for your building automation system.

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 CHAPTER 5

Literature Survey

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 5. LITERATURE SURVEY

5.1. Paper 1
International Journal of Smart Home Vol. 10, No. 1, (2016), pp. 1-8
http://dx.doi.org/10.14257/ijsh.2016.10.1.01
ISSN: 1975-4094 IJSH Copyright ⓒ 2016 SERSC
Research and Design of Coal PLC Control System in Coal-fired Power Plants
Yuheng Yin and Zhongzhe Yue School of Automation, Harbin University of Science and
Technology, Harbin, China Yinyh2009@163.com
Abstract
Coal handling system in thermal power plant is the important component of the auxiliary
system of power plant, it takes on the power plant's power to produce fuel supply missions
with other corresponding mechanical and electrical equipments. During the operation of
thermal power plants, the improvement of working efficiency of coal handling system is the
key factor to improve the work efficiency of the whole power plant, the whole process of
remote monitoring of coal is also put forward higher requirements on the design of automatic
control system, so we choose the most widely used PLC control system in coal handling
system, it makes the dream a reality.
Keywords: thermal power plant; coal handling system; control system; PLC

5.2. Paper 2
International Journal of Advanced Research in Computer Engineering & Technology
(IJARCET) Volume 4 Issue 4, April 2015
R.Keerthika, M.Jagadeeswari
Coal Conveyor Belt Fault Detection and Control in Thermal power plant using PLC
and SCAD

Abstract
Conveyors are seen virtually in the Coal Handling Plant (CHP). CHP are having number of
conveyors. The control systems used for these conveyors are important for operating safe
plant. In order to ensure the belt conveyor operation safe and reliable, centralized monitoring
and control is necessary. The main objective of this proposed system is to monitor and detect
the fault occurring in the coal conveyor belt using PLC and SCADA. Faults such as belt tear
up fault, overloading fault and moisture content fault in the coal conveyor belt are not
identified properly and thus leading to serious damage to the conveyor belt in Thermal Power
Plant. In order to avoid this type of faults, different types of sensors are used in the operation
of PLC and SCADA to provide proper protection for the coal conveyor belt.
Manual control at present is more disadvantageous which leads to frequent tear up, in order
to reduce these tear up and for increasing further enhancements, automation is used. In this
proposed automation system all parameters are processed, controlled, and monitored with the
MMCOE, Department of Electrical Engineering. Page 28
help of DELTA PLC and SCADA WONDERWARE INTOUCH. SCADA is a centralized
system used to supervise a complete plant and basically consists of data accessing features
and controlling processes remotely,
Keywords: Coal conveyor, Delta PLC (Programmable Logic Controller), SCADA
(Supervisory Control and Data Acquisition system) Wonderware In touch.

5.3. Paper 3
International Journal of Advanced Research in Electrical, Electronics and
Instrumentation Engineering (An ISO 3297: 2007 Certified Organization)

Website: www.ijareeie.com
Vol. 6, Issue 3, March 2017
Automatic Coal Conveyor Control Using PLC
Sathish E, Anandkumar P, Vignesh K, Suresh J

Assistant Professor, Dept. of Electronics and Instrumentation Engineering, Erode Sengunthar

Engineering College, Erode, India.
U.G. Student, Dept. of Electronics and Instrumentation Engineering, Erode Sengunthar
Engineering College, Erode, India.

Abstract

In order to ensure the belt conveyor operation safe and reliable, centralized monitoring and
control is very necessary. The main objective of this proposal is to monitor and detect the
fault occurring in the coal conveyor using PLC. Faults such as belt tear up faults, oil level
reduction fault, fire occurrence faults in the belt conveyor are not identified properly and thus
leading to serious damage to the belt conveyor. In order to avoid this type of serious
conditions, we are applying here various types of sensors in their operations using PLC to
provide proper protection for the belt conveyor in Thermal Power Plant. Manual control at
present is more disadvantageous and is being the major reasons for frequent accidents. In
order to reduce these accidents and for increasing further enhancements, automation is used.
All parameters will be processed, controlled, and managed in the coal conveyor with help of
sensors and plc.
Keywords: Coal conveyor, Genie-NX PLC, Sensors.

5.4. Paper 4
International Research Journal of Engineering and Technology (IRJET)
ISSN: 2395 -0056
Volume: 03 Issue: 04 | Apr-2016
www.irjet.net
Study of PLC & SCADA Controlled Thermal Power Plant
Akash R. Jaiswal, Prof. P.P Jagtap

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 GHRCE Nagpur, Professor, Dept. of Electrical Engineering, GHRCE Nagpur, Maharashtra,
India

Abstract
Thermal power plant consist of many important equipment which is required for the
generation such as boiler ,coal conveyer belt ,ash handling plant ,cooling system etc. These
equipment requires continuous inspection and monitoring .this paper outlines the automation
of boiler &coal conveyer .Automation leads to greater efficiency &reliability .The
automation is achieved by using PLC&, SCADA. PLC & SCADA is connected through
communication cable .This paper focuses on passing the inputs to the equipment so that
equipment operation must not get affected .SCADA is used for monitoring the operation of
equipment and PLC is used to control the operation . The different sensors are used to sense
different parameter such as temperature, pressure, tearing of belt, overloading, water level
etc. If the parameter exceed the predetermined value the n it is informed by SCADA system
to the operator.in order to automate the boiler and coal conveyer belt the ladder logic is
developed. The SCADA screen shows the status of equipment so that operator can take
necessary corrective action. In case of emergency different automated check valves are used
to release pressure, steam and inform the concerned authority through alarm. The most
common Faults in coal conveyer belt are belt tear up fault, moisture content and overloading
fault.
Keywords: Communication cables, Programmable Logic Controller (PLC), Power Plant,
Supervisory Control and Data Acquisition system (SCADA).

5.5. Paper 5
International Journal of Computer Trends and Technology (IJCTT)
Volume 18 Number 5 – Dec 2014
Automation of Ash Handling System with Event Logger
Prof. A.S.Wadhawe, Rahul P. Kurtadikar (ME-II)
Head of Electrical Dept. Shri Shivaji inst. of Engineering and Management Parbhani.
SRTMU university nanded (India) Maharashtra.
Abstract

Parli thermal power plant one of the old power plants in Maharashtra. This plant are under
control of MAHAGENCO (MSEB).Parli unit no.3 commissioned in 1984-85.such old power
plant require renovation in order to increase efficiency and output. Main plant renovation is
done in 2004 by using HF CONROL DCS but most of the subsystem was not renovated.
Such as coal handling plant, ash handling plant, water treatment plant etc. it is necessary that
for ash handling plant to be renovate, same done by me by using Programmable Logic
Controller Allen Bradley micro-logix 1500. Embedded I/O and expansion I/O are used.1769
IQ 32 module used as digital input channels.1769 IQ 32 module having 32 digital input.
Another module is OW16, it is digital output module. Having 16 output channels and End
cap or terminator is required at the end of last module.
Keywords: PLC - Programmable logic controller, I/O-Input/output, HP-High pressure.

MMCOE, Department of Electrical Engineering. Page 30

5.6. IEEE Papers
1. Power Plant Coal Conveyor Coal Link PLC Control System.
i. School of Electrical Engineering and Automation, Tianjin China.
ii. Tianjin Entry-Exit Inspection and Quarantine Burean of P.R. China

2. Designing Features of the Coal and ash handling plant.

3. Fault Diagnosis of Coal Ring Crushing Thermal Power Plant: A Case Study.

4. Coal Handling for the Utility Industry.

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 CHAPTER 6

Selection of components and estimation of project cost

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 6. SELECTION OF COMPONENTS AND ESTIMATION OF
PROJECT COST

6.1. Components required

a. PLC - AB series B-1400

b. Relay 8 channel

Relays are switching device. It is the heart of industrial electronic system. Every industrial
electronic system required some type of switching device (or) relay. For the simplest photo-
electric relay to the most advanced.
Depending up on the basic force available for relay contact closing and opening there is
several types of relays.
Some of them are listed below:
1. Electromagnetic or electrodynamics relays
2. Gas or compressed air operated pneumatic relays
3. Heat sensitive bimetallic.

c. Dc geared motor

Description:
60 RPM Side Shaft Super Heavy Duty DC Gear Motor is suitable for bigger robots small
automation systems. It has sturdy construction with large gears. Gear box is built to handle
the stall torque produced by the motor. Drive shaft is supported from both sides with metal
bushes. Motor runs smoothly from 4V to 12V and gives 60 RPM at 12V.High performance
dc geared motors with robust metal gear box for heavy duty applications, available in wide
RPM rangeand ideally suited for robotics and industrial applications.

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d. Centrifugal pump

High quality made, CE passed, mini DC submersible water pump. It is built by brushless
motor which is quieter and last longer. Easy to maintain with fish tank, SOLAR WATER
PUMP, accelerating water circulation, miniature garden, indoor fountain, toys, and other
water circulation system.

e. Push buttons
A push-button is a simple switch mechanism for controlling some aspect of
a machine or a process. Buttons are typically made out of hard material,
usually plastic or metal. The surface is usually flat or shaped to accommodate the human
finger or hand, so as to be easily depressed or pushed. Buttons are most often biased
switches, though even many un-biased buttons require a spring to return to their un-pushed
state. Different people use different terms for the "pushing" of the button, such
as press, depress, mash, hit, and punch.

MMCOE, Department of Electrical Engineering. Page 34

f. Limit switch

The limit switch then regulates the electrical circuit that controls the machine and its moving
parts. These switches can be used as pilot devices for magnetic starter control circuits,
allowing them to start, stop, slow down, or accelerate the functions of an electric motor.

6.2. Estimation of project cost

Components Quantity Price Total price in Rupees.

1. PLC 1 27,000 27,000 /-

2. Push buttons 2 50/Piece 100 /-
3. Indicating lamp 2 65/Piece 130 /-
4. Relay 8 channel 1 350 350 /-
5. Centrifugal pump 1 120 120 /-
6. Dryer motor 1 50 50 /-
9. DC geared motor 4 130/Piece 520 /-
10. Mechanical parts* - 5000 5000 /-

Grand Total of the project = Rs 33,270 /-

Grand Total (Except PLC Panel Components) = Rs 6270 /-

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 CHAPTER 7

Technical specifications of system sub components

MMCOE, Department of Electrical Engineering. Page 36

 7. TECHNICAL SPECIFICATIONS OF SYSTEM SUB
COMPONENTS

Components Specifications of components

1. PLC Allen Bradley 1400 series B

2. push buttons (NO NC Type) 1 Red 1 Green 0-24 VDC, 0-220 VDC

3. Indicating lamp (NO NC Type) 1 Red 1 Green 0-24 VDC, 0-220 VDC

4. Relay 8 channel 12A/120 VAC, 5A/220 VDC , 10A/24 VDC

Rated current – 16.7 mA

5. Centrifugal pump 4.5-12 VDC, Low Torque , 1000 RPM, Imax= 1 amp
Power-3W

6. Dryer motor 4.8-18 VDC, Low Torque , 1000 RPM, Imax= 1 amp

7. Dc geared motor 12 VDC Series motor, High Torque, 60 RPM

Gearbox- Attached Plastic Gearbox
Shaft Diameter- 6mm with internal hole
No load current- 53mA (max)
Load current- 1.2 A (max)

MMCOE, Department of Electrical Engineering. Page 37

 CHAPTER 8

Testing of system sub components

MMCOE, Department of Electrical Engineering. Page 38

 TESTING OF SYSTEM SUB COMPONENTS

Figure (a) Testing of relay channel

PLC Components i.e. indicating lamps, Push buttons, Relay, Toggle switch, LED’s are tested
in our PLC lab. All components are already interface with Allen Bradley Series B 1400 PLC.

Figure (b) Interfacing of plc with computer

Figure (c) Testing of push buttons, indicating lamp, toggle switch and limit switch

MMCOE, Department of Electrical Engineering. Page 39

 Figure (d) Testing of dc geared motor

8.1 . Observation Table:

Components Speed Current in Amp Remark

(Supply=12V DC) in RPM

Dc motor with geared 60 Rpm 0.1 Amp, Motor Run, Tested OK

Imax=1.2 Amp

DC pump motor 1000 Rpm 60mA, Motor Run, Tested OK

Imax=1.2 Amp

Indicating Lamp _ _ Lamp Glow

Dryer fan 1000 Rpm 64 mA, Fan Motor Run, Tested OK

Imax=1amp

MMCOE, Department of Electrical Engineering. Page 40

 CHAPTER 9

Result and Conclusion

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 9. RESULT AND CONCLUSION

This system is safe, reliable, easy to operate, transportation without dust pollution, and
Improves economic and environmental benefits. It has good application value and market
prospect.

SCADA is used for the real time monitoring, thus proposed system gives better accuracy,
time consuming, low power consumption, stable, highly reliable operation in Real-time
where the human life is very important, it protects them from a major risk during fault
condition.
All components are tested and checked interfacing with the PLC in our PLC practical lab,
Dated 15/09/2018.Also all the components are tested as per the specification that we are
selected for PLC.

Thus PLC BASED COAL HANDLING SYSTEM can be successfully implemented

with the use of high end advanced plc technology .The system that is proposed to be
produced can be modified to be better if some of the electrical devices and system are
upgraded and improved. The theory and operation of plc based coal handling system is based
on automatic control system. In electrical design, the features and functions of the electrical
components are required to determine the system requirement. Furthermore, the theoretical of
the wiring system is required for connecting the inputs and outputs devices to PLC. In
programming design, understandings of the desired control system and how to use the Ladder
Diagram to translate the machine sequence of operation are the most important parts, because
it has direct effect on the system performance. Finally, the basis control system and logic
design apply in this project can be used as a references to design other applications of
automation system, not only in the thermal power plants but also in stone crusher areas, and
mining areas and also can be used as a teaching material for the Industrial Control subject.

MMCOE, Department of Electrical Engineering. Page 42

 CHAPTER 10

References

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 10. REFERENCES

10.1. Research paper and books

a] International Journal of Smart Home Vol. 10, No. 1, (2016), pp. 1-8
http://dx.doi.org/10.14257/ijsh.2016.10.1.01
ISSN: 1975-4094 IJSH Copyright ⓒ 2016 SERSC
Research and Design of Coal PLC Control System in Coal-fired Power Plants

b] International Journal of Advanced Research in Computer Engineering & Technology

(IJARCET) Volume 4 Issue 4, April 2015
R.Keerthika, M.Jagadeeswari
Coal Conveyor Belt Fault Detection and Control in Thermal power plant using PLC and
SCADA

c] International Journal of Advanced Research in Electrical, Electronics and Instrumentation

Engineering (An ISO 3297: 2007 Certified Organization)

Website: www.ijareeie.com
Vol. 6, Issue 3, March 2017
Automatic Coal Conveyor Control Using PLC

d] International Research Journal of Engineering and Technology (IRJET)

ISSN: 2395 -0056
Volume: 03 Issue: 04 | Apr-2016
www.irjet.net
Study Of PLC & SCADA Controlled Thermal Power Plant

e] International Journal of Computer Trends and Technology (IJCTT)

Volume 18 Number 5 – Dec 2014
Automation of Ash Handling System with Event Logger

f] IEEE Papers
1. Power Plant Coal Conveyor Coal Link PLC Control System.

MMCOE, Department of Electrical Engineering. Page 44

 i. School of Electrical Engineering and Automation, Tianjin China.
ii. Tianjin Entry-Exit Inspection and Quarantine Burean of P.R. China

2. Designing Features of the Coal and ash handling plant.

3. Fault Diagnosis of Coal Ring Crushing Thermal Power Plant: A Case Study.

4. Coal Handling for the Utility Industry.

g] W. Bolten. ―Programmable Logic Controller‖.

h] Tony-Advanced PLC Programming‖.

i] Rockwell Automation. ― Micrologix 500 user manual‖.

j] PLC and SCADA (theory and practical) book by Rajesh mehara.

10.2. Websites
http://www.slideshare.com
www.allaboutcircuits.com/vol_4
www.elprocus.com
https://www.scribd.com
www.gokul-gardens.in/Concrete_Crush-354.html
https://www.scientific.net/AMR.548.812

MMCOE, Department of Electrical Engineering. Page 45