INDUSTRIAL TRAINING

Reliance Industries Limited (Allahabad Manufacturing Division)

Submitted by:
Prerana Singh Chauhan CSE Final Yr Roll No-30

CONTENTS
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Company Profile Organizational Growth Oregano gram Plant Operation System Description Programmable Logic Control APHS and its networking WSMU IPMS IT Infrastructure at RIL Conclusion

Company Profile
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Situated in Naini industrial area. Earlier known as Raymond Synthetics Limited. It was incorporated on 8th December 1986. Commercial production started in 1991. In year 2000 it was taken over by Reliance Industries Limited and the name of the company was changed to
RELIANCE INDUSTRIES LTD ALLAHABAD MANUFACTURING DIVISION.

It has two plants, batch and continuous process having capacity of 75 tpd and 150 tpd respectively.

Organizational Growth
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RIL started its production of polyester filament yarn in 1991 with the Japanese technology, Toray Engg Corporation. The capacity of the plant was further increased from 25000MT to 70000 MT after the commissioning of CP plant with the same technology. Facilities for production of processed yarn like textured and dyed yarn were later added.

Oregano gram
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RIL Plant is divided into:

 Batch Plant  Continuous Plant Overall in charge of the plant is SITE HEAD.     POLY SPINNING TEXTILE QUALITY ASSURANCE

y PRODUCTION / TECHNICAL Department constitutes:

Plant Operation
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It consists of the following plants such as

Batch Poly : Produces Polyester Chips . Batch Spinning : Produces polyester yarn including colour dope dyed yarn. Textile : Produces Flat yarn and Textured yarn. CP Poly & Spinning: Produces polyester chips and Yarn. APHS : Automatic Product Handling system for Packing operation. Utility : For generation of Steam , Nitrogen , compressed Air, cooling Water , Refrigeration, Primary heating system etc. Power house : For generation of power

Flow Diagram Of Plant Operation

System Description
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RSL1 BOBBIN ADMISSION AREA

Automatic Doffer machine (DF1) Powered Turret Carousel (TC1)

BOBBIN TRANSFER TO HCS AND HCS LOOP y INTERIM STORAGE AREA y PACKING AREA
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PACKING AREA 1 EQUIPMENT AND OPERATION Unloading Doffer (UD1)

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ENCASER E1 WORK CYCLE AND PACKING MATERIAL SUPPLY:

Handling Robot R1

Unloading Doffer(UD1)

Programmable Logic Control

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An important part of automation. Replacement of large spacious and heavy relay logic circuits. Industrially made computer-based unit. Performs discrete or continuous control functions in a variety of processing plant & factory environments. Major manufacturers are: Mitsubishi, Siemens, Omron, Honey well, Telemechanique etc.

Functional Description of PLC

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A programmable logic controllers (PLC) has many common parts:

Structure Of PLC:
There are mainly four very essential parts of the PLC: x 1) CPU x 2) Memory Unit x 3) Programmer x 4) Peripheral Devices

Application Of PLC
The PLC systems are being used in Batch Poly , Batch spinning , Textile machines and APHS , Hyundai DG sets for controlling the processes and equipments. y Following make of PLCs are being used in this plant :
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Siemens Allen Bradley / Rockwell Mitsubishi Fuji electric Omron Schneider electric GE Fanuc

APHS AND ITS NETWORKING

APHS : AUTOMATIC PRODUCT HANDLING SYSTEM
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INTRODUCTION: The system is designed for automated handling and packing of POY and FDY bobbins Coming from the RIL1 and RIL2 production areas. The system makes use (to the maximum extent possible) of reworked and revamped NIFA equipment.

BENEFITS OF APHS
In the Salmoiraghi concept, automation is rather more than a simple reduction of labor costs. y the most important aspect is to completely eliminate manual handling. y The benefits of an Automated Handling System (AHS) are: Complete "from production line to shipping" automation process. Safe and efficient product flow in a compact and fluid system configuration. Data processing facilities, and just-in-time flexibility, High efficiency packing process. Last but not least: safe and physically effortless operation.
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NETWORKING
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All operating stations and PLCs are networked through Ethernet switches using fiber optic cable. 4 nos of switches CISCO 2950 are located in different locations of APHS plant. These switches are then connected to the main switch installed in APHS control room which is finally connected to the main servers in IT department.

WSMU(Winder Setting and Monitoring Unit)

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This system is used for setting the parameters and monitoring of winder performance and running parameters on PC screen in CP Spinning plant. RSL POY-CP WINDER MODEL : TW-536 MIII/8 SUPPLIED BY : TORAY ENGG. CO. JAPAN This acts as a SCADA system for the total 216 winders installed in this plant. the winders are networked to the PC using bus and star topology by the ARCNET data bus.

Block Diagram
WSMU PC
ISA SLOT CPU 386 HD 270 MB WINDOWS VER 3.1

110 VAC/ 50 HZ
ARCNET BOARD

COM20020B-PCAT 30503A

Software version - WSMU - ver 1.73 h ( Rev 1)

HUB card - WDCH-HUB V01 WD 1 HUB BOARD WD 9

WD WD WD

2
WD

8
WD

10
WD

16
WD

17

18

24

Winder Control Panel

PC WSMU

Winder
TW-536 MIII/8 8 ends

Winder Control Panel WCP

HUB BOARD

OTHER PANEL

Specifications
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Winder model is Toray TW 536 M III / 8 and they are 24 nos in one line so there is provision of 24 pos only in wsmu software. Inverter:VS-616P1W Model : CIMR PIW 2014 Input: 220 vac/ 3 phase/51 A Outputs : Sp A: 0-220vac/3 phase/11.4 kva/30 A Make - Yaskawa It is a single unit having 3 different outputs for 2 spindles & 1 TR.

Sequence controller : WDC-H ( consisting of Main PCB , SUB A & SUB B card ) WDCH/GDC - Main - V03 ETC - 610 - 170 N465114 - 009 - 44 MPS 0097 D , Program - WDCH ver. 1.82 WDCH -SUB( B ) - V02 WDCH -SUB( A ) - V03

IPMS(Integrated Plant Manufacturing System Software)

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Four basic operation modules such as Process control, quality control, Packing and utility for data management. New product is created and merged by Process control. Quality Control provides physical test results of finished product and release it to Packing Deptt. Packing deptt packs and weigh the material through IPMS system. Finally data is transferred to SAP through utility module where report generation and MRN operations are performed.

Quality Control Unit Of IPMS

Quality Control

POY Test Data Entry

FDY Test Data Entry

PTY Test Data Entry

POY/FDY/PTY Results Report Daily / Monthly

Packing And Report Generation

IT Utility
Packing

New Quality Code/Desc Entry

Abnormality Of Product Data Entry

Spool Type/Weight Entry

Box Master Pallet Size/ Weight Entry

Weighing Of Packed Box Entry

Daily/Monthly POY/FDY/PTY Reports

Shiftwise Report

Data transfer to SAP

MRN to Packing

IT Infrastructure at RIL_AMD
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Hardwares
Server for APHS: 3 nos , HP make , Model DL380G3, Cap 18GBx2 , speed 2.8 GHZ Server for Production : 2 nos , HP make , Model ML 350 G3 , Cap 36 GBx3 , 733MHZ General server Login : 2 nos , HP make , Model DL380 G5 , cap 146 GBx2 , 3.2 GHZ Total PC : 215 nos + 25 nos. Total printers : 79nos + 20 nos. They are connected with Ethernet based LAN network using UTP/Optical fibre network across the plant.

Softwares At RIL_AMD
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Integrated Plant Manufacturing System (IPMS) developed in-house being used for Packing operation, Laboratory and Process control. Data Acquisition System (DAS) from Yokogawa for CP Spinning parameters. Supervisory Control And Data Acquisition system (SCADA) from Siemens for Hyundai DG Sets performance monitoring and load management. Automatic Package Handling System (APHS) from Salmoiraghi level-1 software for machine operation and level-2 software for plant performance monitoring including laboratory testing data and packaging details and integration with SAP. Energy Management System (EMS) software for power generation and consumption data. ERP SAP R/3 version 6.2D software for all business functions such as FICO module , SD module , PP module , PM module , MM module and HR module etc.

Conclusion
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Networking in plant takes place via

HServer-1:
x Master Server. Comprises all details of the plant x Handles APHS system of the plant effectively. x Communicates with other departments of the plant via switch.

HServer-2:
x Works under HServer-1. x Operates as master in case of failure of HServer-1

DRS (Disaster Recovery Server):

x DRS works in case of failure of HServer-2. x All the backup maintained in HServer-2 is used to configure DRS x DRS is used in case of emergency only very rarely

THANKYOU