KHANNA PAPER MILL

INTRODUCTION:
The Indian Paper Industry is among the top 15 global players today, with an output of more than 6 million tons annually. Paper Industry in India is riding on a strong demand and on an expanding mood to meet the projected demand of 8 million tons by 2010 & 13 million tons by 2020. Demand for paper as well as paper board has increased considerably since independence thus resulting in the setup of a few major paper mills across the country. One of the major players who dominate the paper industry in the Indian sector is Khanna Paper Mills Private Limited. Khanna Paper Mills Private Limited, is an ISO 9001:2000 certified company, manufacturing quality paper and board by recycling of waste paper as the feedstock for domestic consumption for a little over 4 decades. Although paper is traditionally identified with reading and writing, communication has now been replaced by packaging as the single largest category of paper use at 41% of all paper used. Khanna Paper Mills is the largest paper mill production house of its kind and is among the top ten in paper production in India. Khanna today produces around 3,30,000 MT of board and writing and printing paper. Khanna has also become the first paper mill in India to produce high quality writing and printing board from 100% deinked woodfree recovered paper. Khanna Paper Mills distribution network of 100+ dealers has a reach not only over the length and breadth of India but across the globe with a focus on demand markets and exporting their products to the SAARC countries, Africa and the Middle East.

INFRASTRUCTURE:
Khanna Paper Mills believe that the workspace plays a very major role in the productivity of an employee therefore the campus has a unique state-of- the- art infrastructure well equipped with the latest technology. The sprawling 100 acre Khanna Paper Mills campus houses:

Two plants that produce Board with a daily capacity of 400 tons A plant that produces Newsprint with a daily capacity of 400 Tons A plant that produces writing and printing paper with daily capacity of 400 Tons Two plants that produce pulp by recycling of waste paper with a daily production capacity of 350 Tons

PROGRAMMABLE LOGIC CONTROLLER:

A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result. A programmable microprocessor-based device that is used in discrete manufacturing to control assembly lines and machinery on the shop floor as well as many other types of mechanical, electrical and electronic equipment in a plant.

WHAT IS PROCESS CONTROL?

Recognizing the status

Process the Information

Actuate the control Element

Rules and guidelines

The process of recognizing the state of the process at all times, process the information according to the set rules and guidelines and accordingly actuate the control elements is referred to as Process Control. In the control of process, all the sections can be taken manually with human involvement or in semi-automatic or fully automatic manner.

WHAT CONSTITUTES PLC?

The PLC is basically a programmed interfaced between the field input elements like limit switches, sensors, transducers, push buttons etc. and the final control elements like actuators, solenoid valves, dampers, drives, LEDs, hooters etc. Programmable Logic Controller also called as Programmable Controller consists of the following: 1. Input Modules 2. CPU with processor and program memory

3. Output modules 4. Bus system 5. Power supply

Power Supply (1-phase, 230 V, 50 Hz supply)

Input Module

CPU Program Memory

Output Module

Field Input Elements

Control

Process/ Machine

Schematic block diagram of PLC

FUNCTIONS OF VARIOUS BLOCKS THAT MAKE PLC: Input Module:

The input module acts as an interface between the field control inputs and the CPU The voltage or current signals generated by the sensors, transducers, limit switches, push buttons etc are applied to the terminals of the input module. The input module helps in the following ways:

 It converts the field signal into a standard control signal for processing by PLC. The standard control signal delivered by input module could be 5V or 9V whereas the field signal received by Ariit could be 24V DC or 230V AC. If required, it isolates the field signal from the CPU. It sends one input at a time to CPU by multiplexing action thus helping in serial communication. Depending upon the nature of input signal coming from the field, the input module can be Analog Input Module Digital Input Module

Central Processing Unit:

CPU consists of the following blocks: Logic Unit (ALU) Program Memory Process Image Memory (i.e. internal memory of CPU) Internal Timers and Counters Flags

The heart of CPU is its microprocessor/ microcontroller chip. The working of CPU is fully controlled by instructions/ program stored in user program memory. The user program directs and controls the CPUs working. This program is prepared by the user based on the control logic required for the control and automation task.

Arithmetic Logic Unit (ALU):

ALU is the organizer of the PLC The following operations are carried out by ALU: It organizes the input of the external signals and data It performs logic operations with the data It performs calculations It takes account of the value of internal timers and counters. It take account of the signal states of stored in the flags

 It stores the signal states of the input in the Process Input Image (internal memory of CPU) before each program scanning cycle It stores the result of logic operation in the Process Output Image (internal memory of CPU) before each program scanning cycle It organizes the output of the result

Output Module:
The output module acts as a link between CPU and the output devices located in the field The field devices could be relays, contactors, lamps, motorized potentiometers, actuators, solenoid valves, dampers etc. These devices actually control the process. The output module converts the output signal delivered by the CPU into an appropriate voltage level suitable for the output field device. The voltage signal provided by the CPU could be 5 or 9V, but the output module converts this voltage level into 24V DC, or 120V AC or 230V AC etc Thus the Output Module on the receiving signal from the processor switches voltage to the respective output terminals. This makes the actuator or indicating lights etc. connected to the terminal to turn ON or OFF Like an Out Module, an Output Module could be an analog or digital The selection is based on the voltage rating of the field output devices. If the output device is analog, then the analog output module is required and if it is digital like contactor coil or a lamp, then digital output module is required

Bus System:
Bus System is a path for the transmission of signals. In the programmable controllers, it is responsible for the signal exchange between processor and Input/ Output modules. The bus comprises of several signal lines i.e. wire/ tracks There are three buses in a PLC 1. Address bus which enables the selection of memory location or a module 2. Data bus which carries the data from modules to processor and vice versa 3. Control bus which transfer control and timing signal for the synchronization of CPU activities within the programmable controller

Power Supply:
The Power Supply module generates the voltage required for the electronic modules of the PLC from the main supply. Typically 1 phase, 230V AC supply is converted into 24V DC supply by power supply module.

HOW PLC WORKS?

1. Bringing Input Signal Status To The Internal Memory Of CPU The field signals are connected to input module. At the output of input module the field status is converted into a voltage level that is required by the CPU. At the beginning of each cycle the CPU brings in all the field input signals from the input module and stores into its internal memory as process image of input signal. This internal memory of CPU is called as PII, meaning Process Image Input. The programmable controller operates cynically meaning when complete program has been scanned, it starts again at the beginning of the program.

2. Processing Of Signals Using Program & Updating PIQ: Once the field input status is brought input internal memory of CPU , execution of user program, statement by statement begins. Based on user program the CPU performs logical and arithmetic operations on data. It also processes times and counts as well as flag states on instructions.

the the the the

The results of the user program scan i.e. decisions are then stored in the internal memory of CPU. This internal memory is called Process Image Output or PIQ.

3. Sending Process Output Image To Output Module At the end of the program run i.e. at the end of scanning cycle, the CPU transfers the signal states in the process image output to the output module and further to field controls.

WHERE DO WE USE PLC?

In industry, there are many production task which are of highly repetitive nature. Although repetitive and monotonous each stage needs careful attention of operator to ensure good quality of final product. Many a times, close supervision of processes cause high fatigue on operator resulting in loss of track of process control. Sometimes it is hazardous also as in the case of potentially explosive chemical processes. Under all such conditions, we can use PLCs effectively. Some of the capabilities of PLC are as follows: Logic Control Timing, counting, comparison Analog value processing and PID control Real time control Co-ordination and communication Operator control Signaling and listing In short, wherever sequential logic control and automation is desired, the PLCs are best suited to meet the task. It includes simple interlocking functions to complicated analog signal processing to PID control action in closed loop control etc Few examples of industries where PLCs are used for control and automation purposes are listed below: Tyre industry Bulk material handing system at ports Ship unloader Wagon unloader Steel Plants- Blast furnace charging Dairy automation Pulp factory Printing industry etc Today the PLCs are used for control and automation job in a single machine and it increases up to full automation of manufacturing/ testing process in factory.

ADVANTAGES OF PLC:
Reduced Space PLCs are fully solid state and hence extremely compact as compared to hard wired controller wherein electromechanical devices are used. The wiring involved is straight, simple and less

 Energy Saving Average power consumption is just 1/10th of power consumed by an equivalent relay logic control. Ease of Maintenance Modular replacement Easy Trouble Shooting Error diagnostics with programmer supported by software. Economical Considering one time investment PLC is most economical system. The benefits like reduced space, less wiring, low power requirement, lower power time, less down time being fully solid state, highly reliable etc need to be considered when talking about economy Cost of PLC is recovered within a short period. Greater Life and Reliability Static devices hence lesser number of moving parts, reduces wear and tear. In the case of hard wired logic the control, hardware is either electromechanical or pneumatic and therefore it is more prone to faults due to wear and tear of moving parts resulting in lesser ON TIME of the system. Tremendous Flexibility To implement changes in control logic no rewiring is required so considerable time is saved. PLC can carry out complex functions such as generation of time delays, counting, comparing, arithmetic operation, real time control, analog value processing etc. On Line as well as Off line programming is possible High processing speed and great flexibility in the processing of both analog and digital signals Suitability for closed loop tasks with several loops and high sampling frequencies. Shorter Project Time The hard wired control system can be constructed only after the task is fully designed. In the PLC, however, the construction of the controller and wiring are independent of control program definition. This means that the total hardware is standard and desired control is achieved through program. Communication Capabilities The PLC can communicate with other PLCs , auxiliary devices like PC, printer etc. or other compatible devices like drivers

SELECTION OF PLC:
In the market, PLCs with different capacities, capabilities and construction features are available. They are referred to as lower end, middle or higher end PLCs. In selecting the PLC, ask the following questions, get the answers and then decide on which PLC to buy How many control input signals are to be processed by CPU/ PLC? i.e. how many field control signals will be inputted to PLC? How many output devices or controlling elements are to be controlled by CPU/PLC? How many contactors, relays, motorized potentiometers, solenoid valves etc. are to be controlled by PLC? What memory capacity is needed to store the user program? What speed of processing is desired? How many timers/ counters are needed for process control? What are functions/ instructions/ operational capabilities expected from CPU? What are communication requirements? Are there any special or specific requirements including that of safety, reliability and expandability etc? On getting this information check for the specification of the available PLCs/ CPU vis--vis your requirement and then take the decision in the matter.