project siemens sony

Siemens Limited. Infium Digispace Salt Lake, Sector V Kolkata-700091

SONY SENGUPTA

2/2/2014

Industrial Training Report

PLC & Automation

Acknowledgement: -

I, Sony Sengupta pursuing B.TECH in Electronics and Communication Engineering in MCKV Institute of Engineering, Liluah, would like to thank the Department of Electrical and Automation, SIEMENS LTD, Kolkata, for permitting me to undergo an industrial training from January 2nd ,2014 to Jan 31st ,2014.

My learning experience, my understanding of the process of information and technology, my easy access to the projects and my innumerable questions being answered and explained to, has all been possible because of the cooperation and encouragement of all the coordinators and engineers in the Electrical and Automation Department of Siemens India Ltd.

I express my deep gratitude to

� Mr. Aviijit Maitra (Senior Projects Manager)

� Mr .Debasis Mukherjee

� Mr .Moinak Ghosh

� Mr .Amit Das

� Mr .Anupam Mazumdar

� Mr .Sukhendu Das

� Mr. Dipen Mondal.

for sharing their valuable knowledge and guiding me throughout to complete my task effectively.

I also express my sincere thanks to HR Department Manager, Mrs. Barnali Chatterjee who inducted me into the training system.

Regards

Sony Sengupta

Electronics and Communication Engg

MCKV Institute of Engineering

Undergraduate training Report

Student’s Name: Sony Sengupta

Branch: Electronics and communication

Year: 2nd

Semester: 4th

Title of the Project: PLC & Automation

Commencement Date: 2nd January 2014

Completion Date: 31st January 2014

Name of Company/Organisation: Siemens Ltd.

Student’s Signature: ____________________________________

Date:- 3rd February 2014

I certify that Sony Sengupta has satisfactorily completed the Internship and worked on the project referred to above. Her conduct as an intern has been satisfactory in all respects. (Signature of Supervisor)

Supervisor’s Name: Mr. Abhijit Maitra Designation: Senior Manager-Projects Company/Organisation: Siemens Ltd. Company/Organization Seal

Company Overview Steel Making Steelmaking automation Basic Idea of PLC & AUTOMATION I/O List and associated Projects HMI(Human Machine Interface) & projects Conclusion

INTRODUCTION:-

� SIEMENS IN INDIA

The Siemens Group in India has emerged as a leading investor, innovator and implementer of leading-age technology enabled solutions operating in the core business segments of industry, Energy and Healthcare. The Group’s business is represented by various companies that span across these various segments.

Siemens brings to India state-of-the-art-technology that adds value to customers through technology that adds value to customers through a combination of multiple high end technologies for complete solutions.Today, Siemens with its world-class solutions, play a key role in India’s quest for developing modern infrastructure.

SIEMENS BUSINESS SEGMENT

� INDUSTRY AUTOMATION

The range of innovative products, systems and solutions for the distinctive requirements of clients is a varied and diverse as the industry and trade itself. The spectrum of offerings at industry automation ranges from standard products to system solutions for energy and automation technologies used in manufacturing and process industries. As the leading provider industry software, the division optimizes entire value-added change for manufacturing companies-for product design and development, to productions, sales and services.

� DRIVE TECHNOLOGIES

Siemens drive technologies has been enhancing customer productivity and efficiency in industries ranging from aerospace, automobiles, oil and gases to plastics, packaging, logistics and material handling. The division offers complete electrical and mechanical technologies and components including standard and large drives applications covering the entire drive train.

� PRODUCT PORTFOLIO

The Siemens Industry Solutions Division presents its industry-specific product families, which combine plant technology concepts with IT applications and comprehensive services for the operational phase into perfectly coordinated complete packages. Our integrated plant solutions based on selected and proven standards offer customers plug produce convenience for added operating reliability and investment security.

� Areas of Expertise:

� Metals and Mining (MT)

� Iron and steel making

� Rolling mills

� Processing lines

� Continuous and discontinuous mining

� Mineral beneficiation

� Raw material and coal handling plant

� Water technologies (WT)

� High purity water systems

� Process water treatment

� Water disinfection technologies

� Waste water treatment and recycle technologies

� Industrial technologies (IN)

� Cement

� Paper and pulp

� Airports

� Marine

� Cross industries

� Non-ferrous metals

� On-call logistics and maintenance

� Building technologies (BT)

Siemens Building Technologies specializes in meeting the growing demand for increased personal

Safety and more secure public and private infrastructure by electronics security and building automation systems. A market leader providing solutions for “Intelligent Buildings”, the division offers a range of products and services for security, comfort and efficiency in high-end buildings, and covers the entire chain of offerings from engineering to services.

� Mobility (mob)

A pioneer in railways signalling systems in India, Siemens offers products and solutions in railways signalling and safety systems, traffic control and automation, electrification, traction equipment for locomotives and multiple unit system and mass transit vehicles. The product palette also includes rolling stocks and auxiliary inverters for air-conditioned passenger’s coaches. Fully equipped and backed by trained staff, turnkey projects are undertaken for urban transportation, mass rapid transport projects, traction substations overhead centenary and long distance transmission lines.

� Portfolio includes:

� Railways automation

� rail electrification

� turnkey systems

� metros

� Trains and locomotives

� Light rail vehicles

� Multiple units

� Service, maintenance and support for rail systems

� Energy sectors

Siemens consolidates its innovative offerings in Energy Sectors by combining its full range expertise in areas of Power Generation (PG) And Power Transmission & distribution (PTD). Utilizing the most advanced plant diagnostics and systems technologies, Siemens provides comprehensive services for complete power plants and rotating machines such as gas and steam turbines, generators and compressors.

� Power Generation

Efficient, reliable, climate-friendly power generation is vital for economic development. With innovative technologies and products, Siemens is pushing the limits of power plants efficiency and helping strike a viable balance between climate protections, supply-security and cost efficiency in power generation.

From simple cycle power plants, steam power plants up to integrated gasification combined cycle plants, Siemens ensures the highest levels of efficiency currently possible throughout the entire power generation process. The wide range of offerings includes solutions for automation of power grids such as medium voltage switchgear and components.

STEEL MAKING

Steel making is the process of extraction of steel from iron and ferrous scrap.

The properties of steel are closely linked to its composition.

� Properties of steel

Steel can have almost any combination of the following properties-

• LUSTRE • CONDUCTIVITY • MALLEABILITY • DUCTILITY • STRENGTH and DURABILITY

� Types of steel

Steels are a large family of metals. All of them are alloys in which iron is mixed with carbon and other elements. Different types of steel are produced according to the properties required for their application and various gradient systems are used to distinguish steels based on these properties.

Any batch of steel is manufactured according to the customer’s requirement or specification. The specification will produce a steel with the properties that will do the job for which it is required. According to the American Iron and Steel Institute (AISI) , steels can be broadly categorized into four groups based on their chemical compositions:

1. Carbon Steels 2. Alloy Steels 3. Stainless Steels 4. Tool Steels

� General Properties of Steels:

Properties Carbon Steels

Alloy Steels

Stainless Steels

Tool Steels

Density (1000 kg/m3)

7.85 7.85 7.75-8.1 7.72-8.0

Elastic Modulus (GPa)

190-210 190-210

190-210 190-210

Poisson's Ratio 0.27-0.3 0.27-0.3

0.27-0.3 0.27-0.3

Thermal Expansion (10-6/K)

11-16.6 9.0-15 9.0-20.7 9.4-15.1

Melting Point (°C)

1371-1454

Thermal Conductivity (W/m-K)

24.3-65.2 26-48.6 11.2-36.7 19.9-48.3

Specific Heat (J/kg-K)

450-2081 452-1499

420-500

Electrical Resistivity (10-

9W-m)

130-1250 210-1251

75.7-1020

Tensile Strength (MPa)

276-1882 758-1882

515-827 640-2000

Yield Strength (MPa)

186-758 366-1793

207-552 380-440

Percent Elongation (%)

10-32 4-31 12-40 5-25

Hardness (Brinell 3000kg)

86-388 149-627

137-595 210-620

� Basic process of steel making

There are several reactions in iron and steel making process which involves acids and bases. Manufacturing iron removing impurities is the first step in production of steel. Iron is usually made from iron ore, coal and limestone-although some plant around the world have developed alternative method of iron manufacture.

1. Making iron in the blast furnace

The Blast furnace is a large steel structure about 90 meters high. It is lined with refractory firebricks that can withstand temperatures approaching 2000®C .The furnace gets its name from the method that is used to heat it. Preheated air( mainly nitrogen) at about 1000®C is blasted into the furnace through nozzles near its base.

The hot air blast to the furnace burns the coke and maintains the very high temperatures that are needed to reduce the ore to iron. The reaction between air and fuel generates carbon monoxide. This gas reduces the iron (III) oxide in the ore to iron.

Iron(III) oxide + Carbonmonoxide = iron + Carbondioxide

Fe₂O₃(S) + 3CO(g) = 2Fe(s) + 3CO₂(g)

Because the furnace temperature is in the region of 1500®C, the metal is produced in a molten state and this runs down to the base of the furnace. The furnace temperature is also high enough to decompose limestone into calcium oxide.

Calcium carbonate = Calcium oxide + Carbon dioxide

CaCo₃(s) = CaO(s) + CO₂(g)

This oxide helps to remove some of the acidic impurities from the ore.

Calcium oxide + Silica = Calcium silicate

Base Acid Salt

CaO(s) + SiO₂(s) = CaSiO₃(s)

The impurities are removed react with the calcium oxide to make a liquid slag that floats on top of the molten iron. The slag is collected after the denser iron has been run out of a tap hole near the bottom of the furnace.

The production of iron in the blast furnace is a continuous process. The furnace is heated constantly and is recharged with raw materials from the top while it is being tapped from the bottom. Iron making in the furnace is usually continues for about ten years before the furnace lining have to be renewed.

The energy costs of the operation are kept to a minimum by collecting and cleaning the hot gas that leaves the furnace. The gas contains a lot of carbon monoxide. It can be re-used as a fuel for other steelmaking processes or to heat up the air blast to the furnace.

2. Refining iron

The metal that leaves the Blast furnace contains between 4% to 5% of carbon. This much carbon is makes a very hard brittle metal which is not much use. The next step in the production of steel is to reduce the levels of the carbon and other impurity elements in the hot metal.

3. Heat treatment

Heat treatment given to steel can affect its properties too. Cooling of red-hot tool steel rapidly in cold water makes it harder and more brittle. We could have made the same piece of metal softer by keeping it at red-heat foe longer and then cooling it slowly. Heat treatment is another method that steelmaker uses to make the properties of the steel match the job it has to do.

Routes to steel

Two methods of making steel are dominant in modern steel industries all over the world.

• Route1: Basic Oxygen Steelmaking(BOS)

The hot metal from Blast furnace contains up to 4.5% of carbon. Steelmaking reduces the carbon content to a level that matches the customer’s requirements. This is often less than 0.1%. Basic Oxygen Steelmaking (BOS) makes steel from the Blast furnace iron and small amount of scrap metal. Most of the metal that is made in the BOS furnace is sold as bulk steel.

Blast furnace iron + scrap BOSFurnace Steel

The figure shows oxygen being blown into the furnace or BOS vessel through a water cooled oxygen lance. This oxidizes carbon and the other unwanted elements in the hot metal. The carbon is oxidized to carbon monoxide gas, which passes from the converter to a cooling plant. After cleaning, it can be re-used as a fuel gas. The rest of elements in the metal are converted to acidic oxides. They combined with the lime and other fluxes that are added during the blow. This produces a slag that floats on the surface of the metal.

The steel is tapped from the furnace when it is in correct temperature and composition. The furnace is tilted and the molten metal is run out via the tap

hole into the ladle. Once the steel has been removed, the furnace is turned upside down and the slag that is left inside runs into another ladle. The solidified slag can be used in the production of cement and as an aggregate in road building.

� Basic oxygen sequence :- I. BOS converter is charged first with the scrap. This is used as a

coolant. It is used to control the very high temperatures produced by the violently exothermic reactions in the furnace.

II. Blowing: After charging, the furnace is blown by blasting oxygen through a lance that is lowered into the molten metal. The furnace needs no heating. Carbon is oxidized to CO and much of the carbon in the metal escapes as this gas. Slag is formed is this stage.

III. After blow has continued for about 20 minutes, the metal is sampled. The BOS process is now complete the furnace can be tapped . Steel is run out of the tap hole into a ladle, separating it from the lighter slag, which is later emptied as waste.

� Removing gases and making it uniform:-

Some oxygen dissolves in the steel when the furnace is blown. Adding small amounts of aluminum will remove the oxygen as aluminum oxide. This solid forms a slag on the surface of the steel that is removed before the metal is cast. The gases can be removed by vacuum degassing. This involves shaking the molten metal at very low pressures, which allows dissolved impurity gases, such as oxygen, to escape from the molten metal.

Next, the metal is stirred by blowing it with argon gas.This ensures that the composition of the metal is uniform. Stirring also helps to even out the temperature throughout the liquid metal. The temperature is a critical factor when the metal is being cast. The ladle arc furnace in the picture can be used to adjust the temperature of the metal before casting.

Once steel of the correct specification has been made, it is ready for casting. This way of giving the metal the basic shape that the customer wants. In the past, it was usual to cast the molten steel from a ladle into moulds called ingots.

The steel was then shaped after it had solidified in the mould. This required re-heating the ingot to soften it and then rolling in a steel mill.

� Continuous casting:- The modern steel industry uses continuous casting, which is more efficient. This technique allows molten steel from the ladle to be cast directly into the basic shape that the customer wants. By adjusting the water-cooled moulds in the continuous caster, steel sections can be produced in the three basic shapes shown on the right: slabs, blooms and billets.

The Basic Oxygen Steelmaking Process is the UK's major method for making steel. Modern furnaces will take a charge of up to 350 tonnes and convert it into steel in less than 40 minutes.

� Route 2: Electric Arc Furnace (EAF)

We also make steel in the UK using the Electric Arc Furnace (EAF). This is an electrically heated furnace that makes steel from scrap metal only.

Scrap EAF furnace Steel

The Electric Arc Furnace (EAF) offers an alternative method of bulk steel manufacture. It makes steel from what would otherwise be unsightly and environmentally damaging scrap metals. It also consumes much less energy than the BOS furnace. Every tonne of EAF steel uses about 7.4 GJ of energy compared with about 16.2 GJ for every tonne of BOS steel.

� Furnace design The EAF is a kettle-shaped structure with a removable lid. The three graphite electrodes that heat the furnace pass through this lid, which can be swung back when the furnace is being charged. The hearth of the EAF where the metal is melted, is lined with a chemically basic and refractory material.

The sequence of operations is similar to that in the BOS furnace, except that, after charging, the charge must be melted down. The furnace charge melts when an electric arc passes between the electrodes and the scrap metal. The temperature around the arc rises to 1200® C and a 100 tonnes charge can be melted in about 60 minutes.

RH- Degasser: R is the short form of Ruhrstahl. The first RH degasser was developed and installed at the steelmaking company Ruhrstahl AG, Germany. H is the short form of Heraeus . Heraeus was the main supplier of vaccum pumps and constructed the vaccum pums for RH Degasser. The RH-Degasser will be installed to fulfill the following tasks:

• Degassing • Decarburization • Chemical composition adjustments • Temperature adjustments • Vessel heating

Process description: HYDROGEN REMOVAL: the final hydrogen content of a heat depends on the pressure of vaccum vessel, the amount of lift gas and CO gas development. Even fully killed heats can be treated due to intensive degassing supported by lift gas. For lowest hydrogen level the pressure must be lower than 2 mbar with according treatment times 15-20 mins.

LIGHT TREATMENT: The liquid steel will be tapped un-killed or semi-killed from convertor and partly deoxidized in the RH plant. The deoxidization will occur due to the CO development by natural decarburization. The pressure range depends on the CO equilibrium and is about 200-400mbar. After 10-12 mins treatment the final de-oxidation process will be carried out with Al or others. OXYGEN BLOWING PROCESS:- Forced Decarburization and heating of unkilled heats. For the forced decarburization, oxygen will be blown only for a few minutes in the pressure range of 5-30kpa. Heating of unkilled heats will be executed during the decarburization process in case oxygen is blown for decarburization, the blowing time will be extended until the required amount of heat is added. The SIMENTAL oxygen blowing process features are short blowing time with optimum oxygen efficiency. CHEMICAL HEATING OF KILLED HEATS:- The Chemical heating process is based on the fundamentals of exothermic process. In order to save alloying agents such as C, Mn etc heating of killed heats will be conducted by a batch additrion of aluminium and subsequent oxygen blowing. QUICK DESKULLING BY OXYGEN JET: - Between the treatments the oxygen jet can be used for a quick vessel deskulling. The deskulliong will be executed for 10 or 15 minutres and large amount of skull can be removed.

STEEL MAKING PROCESS IN BRIEF

Steel Making Automation

Steelmaking automation supplies state-of-the-art solutions for maximum performance and product quality throughout the entire steel plant.

The unique advantage of this integrated approach is that it covers the aspects of process stability, product quality and operation flexibility, while safeguarding efficiency and profitability throughout the entire plant li fe-cycle. Decades of experience with steelmaking technology, combined with extensive automation expertise, is the basis for highly advanced automation systems for every plant unit. Proven solutions for power supply, drives, technological packages and process optimization enable smooth production and the intelli gent use of energy and raw materials. And forward- looking service concepts ensure continuous high availability of plant and equipment. Your investment is protected by our standardized overall design with clear-cut interfaces.

� PLC (PROGRAMMABLE LOGIC CONTROLLER)

PLC stands for programmable logic controllers. They are also referred to as Programmable Controllers. They are used in commercial and industrial applications. A PLC monitors inputs, makes decision based on it program, and controls the output to automate a process or a machine.

• Basic operation of PLC

PLCs consist of input modules or points, a Central Processing Unit (CPU), and output modules or points. An input accepts a variety of digital or analog signals from various field devices (sensors) and converts them into a logic signal that can be used by the CPU. The CPU makes decisions and executes control instructions based on program instructions in memory. Output modules convert control instructions from the CPU into a digital or analog signal that can be used to control various field devices (actuators). A programming device is used to input the desired instructions. These instructions determine what the PLC will do for a specific input. An operator interface device allows process information to be displayed and new control parameters to be entered.

Input

module

Central processing

unit (CPU)

Output

module

Programming Device

Operating Interface

� HARD-WIRED CONTROL

Before PLCs came into the picture, many control tasks were performed using contactor or relay controls. This is often considered as ‘Hard-wired Control’.

� Advantages of PLC

• Smaller physical size than hard-wire solutions.

• Easier and faster to make changes.

• PLCs have integrated diagnostics and override functions.

• Diagnostics are centrally available.

• Applications can be immediately documented.

• Applications can be duplicated faster and less expensively

� Siemens PLCs

Siemens makes several PLC product lines in the SIMATIC S7 family. They are: S7-200, S7-300, and S7-400

• S7-200

The S7-200 is referred to as a micro PLC because of its small size. The S7-200 has a brick design which means that the power supply and I/O are on-board. The S7-200 can be used on smaller, stand-alone applications such as elevators, car washes, or mixing machines. It can also be used on more complex industrial applications such as bottling and packaging machines,

• S7-300 and S7-400

The S7-300 and S7-400 PLCs are used in more complex applications that support a greater number of I/O points. Both PLCs are modular and expandable. The power supply and I/O consist of separate modules connected to the CPU. Choosing either the S7-300 or S7-400 depends on the complexity of the task and possible future expansion. Your Siemens sales representative can provide you with additional information on any of the Siemens PLCs.

� TERMINOLOGY

The language of PLCs consists of a commonly used set of terms; many of which are unique to PLCs. In order to understand the ideas and concepts of PLCs, an understanding of these terms is necessary.

• Sensors-

A sensor is a device that converts a physical condition into an electrical signal for use by the PLC. Sensors are connected to the input of a PLC. A pushbutton is one example of a sensor that is connected to the PLC input. An electrical signal is sent from the pushbutton to the PLC indicating the condition (open/closed) of the pushbutton contacts.

• Actuators-

Actuators convert an electrical signal from the PLC into a physical condition. Actuators are connected to the PLC output. A motor starter is one example of an actuator that is connected to the PLC output. Depending on the output PLC signal the motor starter will either start or stop the motor.

PLC

PLC MOTOR

• Discrete Input-

A discrete input, also referred to as a digital input, is an input that is either in an ON or OFF condition. Pushbuttons, toggle switches, limit switches, proximity switches, and contact closures are examples of discrete sensors which are connected to the PLCs discrete or digital inputs. In the ON condition a discrete input may be referred to as logic 1 or logic high. In the OFF condition a discrete input may be referred to as

.

A Normally Open (NO) pushbutton is used in the following example. One side of the pushbutton is connected to the first PLC input. The other side of the pushbutton is connected to an internal 24 VDC power supply. Many PLCs require a separate power supply to power the inputs. In the open state, no voltage is present at the PLC input. This is the OFF condition. When the pushbutton is depressed, 24 VDC is applied to the PLC input. This is the ON condition.

• Analog inputs-

An analog input is an input signal that has a continuous signal. Typical analog inputs may vary from 0 to 20 milliamps, 4 to 20 milliamps, or 0 to 10 volts. In the following example, a level transmitter monitors the level of liquid in a tank. Depending on the level transmitter, the signal to the PLC can either increase or decrease as the level increases or decreases.

• Discrete output-

A discrete output is an output that is either in an ON or OFF condition. Solenoids, contactor coils, and lamps are examples of actuator devices connected to discrete outputs. Discrete outputs may also be referred to as digital outputs. In the following example, a lamp can be turned on or off by the PLC output it is connected to.

• Analog output-

An analog output is an output signal that has a continuous signal. The output may be as simple as a 0-10 VDC level that drives an analog meter. Examples of analog meter outputs are speed, weight, and temperature. The output signal may also be used on more complex applications such as a current-to pneumatic transducer that controls an air-operated flow-control valve.

• CPU-

The central processor unit (CPU) is a microprocessor system that contains the system memory and is the PLC decision making unit. The CPU monitors the inputs and makes decisions based on instructions held in the program memory. The CPU performs relay, counting, timing, data comparison, and sequential operations.

• Programming-

A program consists of one or more instructions that accomplish a task. Programming a PLC is simply constructing a set of instructions. There are several ways to look at a program such as ladder logic, statement lists, or function block diagrams.

• Ladder logic-Ladder logic (LAD) is one programming language used with PLCs. Ladder logic uses components that resemble elements used in a line diagram format to describe hard-wired control. Refer to the STEP 2000

course Basics of Control Components for more information on line diagrams.

• Ladder Logic Diagram-

The left vertical line of a ladder logic diagram represents the power or energized conductor. The output element or instruction represents the neutral or return path of the circuit. The right vertical line, which represents the return path on a hard-wired control line diagram, is omitted. Ladder logic diagrams are read from left-to right, top-to-bottom. Rungs are sometimes referred to as networks. A network may have several control elements, but only one output coil.

Expanding the Application The application can be easily expanded to include indicator lights for RUN and STOP conditions. In this example a RUN indicator light is connected to output Q0.1 and a STOP indicator light is connected to output Q0.2. It can be seen from the ladder logic that a normally open output Q0.0 is connected on Network 2 to output Q0.1 and a normally closed Q0.0 contact is connected to output Q0.2 on network 3. In a stopped condition output Q0.0 is off. The normally open Q0.0 contacts on Network 2 are open and the RUN indicator, connected to output Q0.1 light is off. The normally closed Q0.1 on Network 3 lights are closed and the STOP indicator light,

connected to output Q0.2 is on.

� I/O LIST:-

I/O List is a document containing list of instrumentation which serve as an input or output of control system. Therefore, only the tag number that physically has a cable which connects to the control system appears on I/O List.

In I/O list, the following information are generally stated

� Tag number � Loop Number � Service description � P&ID Number � Type of Instrument � Location � I/O Type � Control System � Range or set point

The task with which we were associated was to identify the instruments from the P&I Diagrams of different parts of the RH - Degasser plant and fill up the corresponding Tag and Instrument numbers along with its description in the I/O list.

� Twin RH Degasser.

The other type of task we performed was to fill up the function description list from the corresponding I/O List and P&I Diagrams.

� I/O List:-

� Function Description List:-

� HMI (Human Machine Interface)

Definition: The term HMI is used mostly in a manufacturing environment. The human-machine interface (HMI) is where people and technology meet on the plant floor. The HMI can be as simple as the grip on a drill or as complex as the controls of an automated packing line.

This layer where humans and technology meet actually separates the human operating the machine from the machine(s) itself. A good HMI should aid the human in mentally mapping out the task needing to be performed with the machine. The use of the HMI itself should be self evident or intuitive.

In manufacturing, a typical HMI could be a button that initiates a sequence of events or a process. Or, a Windows based computer that uses software to interface the human and the PLC, which initiates, stops or somehow controls actions of a machine.

The user interface, in the industrial field of human machine-interaction, is the space where interaction between humans and machines occurs. The goal of interaction between a human and a machine at the user interface is effective operation and control of the machine, and feedback from the machine which aids the operator in making operational decisions. Examples of this broad concept of user interfaces include the interactive aspects of computer operating systemshttp://en.wikipedia.org/wiki/Operating_system, hand tools, heavy machinery operator controls, and process controls. The design considerations applicable when creating user interfaces are related to or involve such disciplines as ergonomics and psychology.

. The user interface includes hardware (physical) and software (logical) components. User interfaces exist for various systems, and provide a means of: A user interface is the system by which people (users) interact with a machine

• Input, allowing the users to manipulate a system • Output, allowing the system to indicate the effects of the users'

manipulation

Generally, the goal of human-machine interaction engineering is to produce a user interface which makes it easy, efficient, and enjoyable to operate a machine in the way which produces the desired result. This generally means that the operator needs to provide minimal input to achieve the desired output, and also that the machine minimizes undesired outputs to the human.

Ever since the increased use of personal computers and the relative decline in societal awareness of heavy machinery, the term user interface has taken on overtones of the graphical user interface, while industrial control panel and machinery control design discussions more commonly refer to human-machine interfaces.

Other terms for user interface include human–computer interface (HCI ) and man–machine interface (MMI).

SIMATIC WinCC is a supervisory control and data acquisition (SCADA) and HMI system from Siemens. It can be used in combination with Siemens PCS7 and Teleperm control systems. WinCC is written for Microsoft Windows operating system. WinCC uses Microsoft SQL Server for logging and comes with a VBScript and ANSI C Application Programming Interface.

WinCC and PCS 7 are the first SCADA systems to be specifically targeted by malware. The Stuxnet worm can spy on and even reprogram infected systems.

Some other HMI softwares are iFIXfrom Intellution and RSView from Rockwell Software.Micro Panel, Mobile Panel, Personal Computer servers can be used as HMI hardware.

Conclusion: Human-machine interface is probably the sector in automation which has made the greatest progress in the last few years. This progress is due to increasingly sophisticated and user-friendly electronics and signal processing. With the right choice of interface and its configuration, users can control processes with ever greater exactness and undertake diagnostics and preventive maintenance to increase productivity by reducing downtime.

The projects we have performed on the HMI Sinter Plant have been attached herewith.

� Project 1:-

Mixed Material Preparation System

With the help of a software provided by SIEMENS, accurate diagrams were drawn as a soft copy which later with the help of PLC’s are used to execute a plant’s design and its control.

As your single-source provider, Siemens’ human machine interface technology SIMATIC HMI is engineered to meet the increasingly complex processes of your machines and systems. SIMATIC HMI is optimized to meet your specific human machine interface needs using open and standardized interfaces in hardware and software, which allow efficient integration into your automation systems.

� Project 2:

Pipe & Instrument Diagram:-

� Project 3:-

P&I Diagram for Plant Dedusting ESP:

� Project 4:-

Waste Gas Cleaning System

� Project 5:-

Waste Gas Cleaning System-Dust Transport

Conclusion:-

Various things were learnt through this industrial internship at Siemens. It was a great privilege for me to get a golden opportunity for training in SIEMENS VAI METALS TECHNOLOGIES PVT LTD. I got to see practical implications of what I have studied in my engineering course. It was a chance for me to learn how things work in industries & to get the feel of corporate world.

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