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Training Report On Automation Division Submitted in the partial fulfillment of the requirement for the award of degree of Bachelors of Technology In Electronics & Communication Engineering Submitted by:
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Page 1: Training Report

Training Report

On

Automation Division

Submitted in the partial fulfillment of the requirement for the award of degree of

Bachelors of Technology

In

Electronics & Communication Engineering

Submitted by:

PANKAJ SAHUReg. Number: 10907659

RDCIS ,STEEL AUTORITY OF INDIA LIMITED ,RANCHI 834002Period Training: 02/06/2012- 16/07/2012

Department of Electronics & Comm. EnggLovely Professional University

Certificate

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Certified that this Training entitled “Automation Division” submitted by Pankaj sahu (Reg no

10907659), students of Electronics & Communication Engineering Department, Lovely

Professional University, Phagwara Punjab in the partial fulfillment of the requirement for the

award of Bachelors of Technology (Electronics & Communication Engineering) Degree of LPU,

is a record of student’s own study carried under my supervision & guidance.

Sunil kumar saw

Sr. Manager & Incharge (HRD).

ACKNOWLEDGEMENT

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I sincerely thank RDCIS, SAIL to allow me to undergo my vocational training in the same. It was a great learning experience. I encountered difficulties but with the continuous support of RDCIS, I was able to overcome them.I also thank Mrs Archana mam , DGM & HOD of Automation, for providing us the opportunity to undergo training in this pioneering campus.

I also thank Mr. B.N. Ghosh (AGM), Mr. S. Mazumdar (AGM) and Mrs.A.Sharan (Senior Manager) of process automation group for their helpful guidance and support without whom our training would not been completed successfully.I am also grateful to Mr.A.K. Sinha, Telephone Exchange, who provided me the necessary technical review. I am grateful to the H.R.D. Division of RDCIS, SAIL, especially Mr. Sunil kumar saw Sr. Manager & Incharge (HRD).

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CONTENTS

ABOUT THE ORGANISATION

TELEPHONE EXCHANGE-

o Introduction

o 1000 line EPABX system

o Functions of SLICA card

o Special features of RDCIS, SAIL Telephone Exchange

PROGRAMMABLE LOGIC CONTROLLLER (PLC)

o Introduction.

o Operation.

o Software used with programming language.

o Input/Output devices.

o Hardwired systems.

o Manual operation vs. Automated systems.

o Building blocks of an automated systems.

o Hardwire components of a PLC.

o Method of programming.

o Designed PLC for given logic

.

LEARNING OUTCOMES & ANALYSIS

CONCLUSIONS

FUTURE SCOPE OF THIS TYPE TRAINING

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COMPANY’s PROFILE

STEEL AUTHORITY OF INDIA LIMITED

History

SAIL traces its origin to the formatives years of an emerging nation - India. After independence the bull modern India worked with the vision- to lay the infrastructure for rapid industrialization of country. This sector was to propel the economic growth. Hindustan steel private limited was set up on January 19, 1958.The president of India held the shares of the Company on behalf of the people of India.

Expanding Horizon (1959-1973)

Hindustan Steel Limited (HSL) was initially designed to manage only one plant that was coming up at Rourkela. Durgapur steel plants, the preliminary work was done by the Iron & Steel Ministry. From April 1954 the supervision and control of the steel plants were also transferred to Hindustan Steel. The registration was only in New Delhi. It moved to Kolkata in July 1956 and ultimately to Ranchi in December 1959.

A new company, Bokaro Steel Limited, was incorporated in January 1964 to construct and operate the plant of Bokaro. The I MT phases Bhilai and Rourkela Steel Plants were completed by the end of December 1961.The I MT phases of Durgapur Steel Plant was completed in January 1962 after commissioning of the Axle Plant. The crude steel production of HSL went up from .158 MT (1959-60) to 1.6 MT .The second largest of Bhilai Steel Plants was completed in September in 1967 after commissioning of the Wire Rod Mill.The 1.8 MT phases of Rourkela - the Tandem Mill-was commissioned in February 1968, the 1.6MT phases of Durgapur Steel Plant was completed in August 1969 after commissioning of Furnace in SMS. Thus the completionof the 2.5MTstage at Bhilai, 1.8MT at Rourkela and 1.6MT at Durgapur, the total crude production capacity Of HSL was raised to 3.7MT in 1968-1969 and subsequently to 4MT in 1972-73.Integrated Steel Plants

Bhilai Steel Plant (BSP)

Seven - time winner of Prime Minister’s Trophy for best Integrated Steel Plant in the country, Bhilai Steel Plant (BSP) is India’s sole producer of rails and heavy steel plates and major producer of structural. The plant is the sole supplier of the country's longest rail tracks of 260 metres. With an annual production capacity of 3.153 MT of saleable steel, the plant also specializes in other products such as wire rods and merchant products. Since BSP is accredited with ISO 9001:2000 Quality Management System Standard, all saleable products of Bhilai Steel Plant come under the ISO umbrella.

At Bhilai IS0:14001 has been awarded for Environment Management System in the Plant, Township and Dalli Mines and it is the only steel plant to get certification in all

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these areas. The Plant is accredited with SA: 8000 certification for social accountability and the OHSAS-18001 certification for Occupational health and safety. These internationally recognised certifications add value to Bhilai’s products and helps create a place among the best organisations in the steel industry.

Location: Forty kms west of Raipur, the capital city of Chhattisgarh, along the Howrah-Mumbai railway line and the Great-Eastern highway stands Bhilai Steel Plant (BSP).

Rourkela Steel Plant

Rourkela Steel Plant (RSP), the first integrated steel plant in the Public Sector in India, was set up with German collaboration with an installed capacity of 1 million tonnes. Subsequently, the capacity was enhanced to 1.9 million tonnes.

The plant was modernized in the mid 1990s with a number of new units with state-of -the-art facilities. Most of the old units have also been revamped for effecting substantial improvement in the quality of products, reducing the cost and ensuring cleaner environment.The present capacity of the Plant is 2 million tonnes of Hot Metal, 1.9 million tons of Crude Steel and 1.671 million tonnes of Saleable Steel. Its wide and sophisticated product range includes various flat, tubular and coated products.

Location: Rourkela Steel Plant is located in the north-western tip of Orissa and at the heart of a rich mineral belt. Being situated on the Howrah-Mumbai mainline, Rourkela is very well connected with most of the important cities of India. The nearby airports are Ranchi (173 km), Bhubaneswar (378 km) and Kolkata (413KM). Rourkela also has an Airstrip maintained by Rourkela Steel Plant.

Bokaro Steel Plant (BSL):The fourth integrated plant in the Public Sector - started taking shape in 1965 in collaboration with the Soviet Union. It was originally incorporated as a limited company on 29th January 1964, and was later merged with SAIL, first as a subsidiary and then as a unit, through the Public Sector Iron & Steel Companies (Restructuring & Miscellaneous Provisions) Act 1978. The construction work started on 6th April 1968.

The Plant is hailed as the country’s first Swadeshi steel plant, built with maximum indigenous content in terms of equipment, material and know-how. Its first Blast Furnace started on 2nd October 1972 and the first phase of 1.7 MT ingot steel was completed on 26th February 1978 with the commissioning of the third Blast Furnace. All units of 4 MT stage have already been commissioned and the 90s' modernisation has further upgraded this to 4.5 MT of liquid steel.

The new features added in modernisation of SMS-II include two twin-strand slab casters along with a Steel Refining Unit. The Steel Refining Unit was inaugurated on 19th September, 1997 and the Continuous Casting Machine on 25th April, 1998. The

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modernisation of the Hot Strip Mill saw addition of new features like high pressure de-scalers, work roll bending, hydraulic automatic gauge control, quick work roll change, laminar cooling etc. New walking beam reheating furnaces are replacing the less efficient pusher type furnaces.

Durgapur Steel Plant:

Set up in the late 50's with an initial annual capacity of one million tones of crude steel per year, the capacity of Durgapur Steel Plant (DSP) was later expanded to 1.6 million tonnes in the 70's. A massive modernisation programme was undertaken in the plant in early 90's, which, while bringing numerous technological developments in the plant, enhanced the capacity of the plant to 2.088 million tonnes of hot metal, 1.8 million tonnes crude steel and 1.586 million tonnes saleable steel. The entire plant is covered under ISO9001: 2000 quality management system.

The modernized DSP now has state-of –the-art technology for quality steel making. The modernized units have brought about improved productivity, substantial improvement in energy conservation and better quality products. DSP’s Steel Making complex and the entire mills zone, comprising its Blooming & Billet Mill, Merchant Mill, Skelp Mill, Section Mill and Wheel & Axle Plant, are covered under ISO: 9002 quality assurance certification.

With the successful commissioning of the modernized units, DSP is all set to produce 2.088 million tones of hot metal, 1.8 million tones of crude steel and 1.586 million tones of saleable steel annually.

Location: Situated at a distance of 158 km from Calcutta, its geographical location is defined as 230 27' North and 880 29' East. It is situated on the banks of the Damodar River. The Grand Trunk Road and the main Calcutta-Delhi railway line pass through Durgapur.

Research & Development Centre for Iron & Steel, SAIL, RANCHI

The Research and Development Centre for Iron and Steel (RDCIS), the corporate R&D unit of Steel Authority of India Limited (SAIL), was set up in the year 1972. An ISO: 9000-2001 certified research and development centre for Iron and Steel undertakes R&D projects in diverse realms of iron and steel under the categories of basic scientific research, plant performance improvement, investigation and consultancy assignment equipments instrumental design and major technology development.

RDCIS has more than 300 dedicated and competent scientists and engineers and its laboratory is equipped with around 350 sophisticated diagnostic research equipment and 6 pilot plant facilities. The primary objective of RDCIS is to plan and implement

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research and development programs in all the steel plants of SAIL in order to achieve continuous improvement in the critical performance indices of the plants. The centre has made the significant contribution towards the achievement of the objective through process improvement, energy conservation, cost reduction, quality improvements, development of the new and value added products and introduction of new technology.

The major efforts of RDCIS are directed towards cost reduction, quality improvement and value addition to products of the SAIL plants and providing application engineering support at customer end. Along with the steel plants, RDCIS has taken initiatives to pursue multidisciplinary large projects with an aim to improve overall performance of the plants and to develop special products for prospective customers.

RDCIS also offers technology services to various organizations in the form of know how transfer of technologies development by it, consultancy services, specialized testing services, contract research and technology awareness program. As a result of re-orientation of to accelerate the pace of change and to provide support to company on major technological issues, RDCIS is providing greater thrust to the following areas;

In depth analysis followed by evolving strategies option on major technological issues of the company.

Assessment of the market-product-technology linkage and development of new products together with steel plants and CMO.

Enhancement of consumption of SAIL steel through extensive application engineering efforts aimed at the existing as well as the as the potential customers.

Re-enforcement of activities of 5technology dissemination centre with increased interaction and collaboration with plant training centres in order to augment the technological training in the company.

Consultancy service to the organization outside SAIL and enhanced efforts to market technologies and know development in the house.

The vision, goals, quality, policy and credo of the quoted below.

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VISION OF RDCIS

“Achieve excellence in technological expertise and to fulfil the needs of the steel plants and customers”

GOALS OF RDCIS

Obtain 75% of its annual budget from the SAIL plants through pursuit of plant based on R&D projects and the balance 25% from SAIL corporate office.

Develop market specific products in line with changing consumption pattern of steel and exports plant of SAIL.

Develop competence of an international level in specific technological area.

File every year an average of 4 international and 10 national patents and publish 25 papers in journals of internationally excellent standards.

Integrated Steel Plants

Bhilai Steel Plant (BSP)in Chhattisgarh

Durgapur Steel Plant (DSP) in West Bengal

Rourkela Steel Plant (RSP) in Orissa

Bokaro Steel Plant (BSL) in Jharkhand

IISCO Steel Plant (ISP) in West Bengal

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INTRODUCTIONTELEPHONE SYSTEM

The telephone system is an important part of many data communi-cations systems. Although it is in many ways less than ideal for data communications, telephone connections are everywhere. The telephone system is often used for the same reason.

Understanding how the phone system is used for data communications requires knowledge of the technical aspects of the phone system. The areas of most interest are the nature of signals on the phone lines, functions of the phone company local office, characteristics of phone wires, and dialing. The connection between a data communications device and the phone system requires a device called modem, which puts data signals into an electrical form compatible with the analog phone system. Modems are available in several forms, both physically and electrically. Although they have performance limitations based on the limitations and operation of the phone for the user application. Modern integrated circuits (ICs) allow modems to offer greater performance in smaller space, with lower power use and cost, than earlier-generation modems.

Basic Telephone Service

The telephone and its system are things that most people take for granted. The telephone system covers the United States, Canada, most of the Western Hemisphere, Europe, and other parts of the globe. There are only a few places where there is not some level of phone service.

As a system, the telephone system is extremely complicated. There are many technical subtleties and advanced types of technology that make this system work smoothly, efficiently and reliably on a countrywide and worldwide basis. However, there are some interface issues that affect every user, technician, or engineer who is attempting to use the telephone system for the communication of data.

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The use of the telephone system and lines for communication of data is often referred to as telecommunications. The telephone system is available nearly everywhere. The connections that equipment should make to the system are standardized throughout the country, and therefore the same interface connectors, signals, and formats can be used easily in any location. The system is relatively low in cost, compared to the value it provides and the cost of the trying to build a duplicate system. It may not be perfect, but it is acceptable enough, with low effort, for many types of applications, especially when there is some reasonable distance to cover, such as between adjacent buildings or neighboring towns, or across the country or world.

The drawbacks of the telephone system is that the performance that can be achieved with regular phone lines is often less than the application really demands. Since the phone system was designed for analog voice signals, it is internally optimized for non-digital signals. Some performance compromises must be made to use it for data.

The phone system is an open system and so special steps must be taken to prevent unauthorized users from “tapping in” to private data. It is certainly possible to prevent them, but doing so costs more money.

Finally, since the phone system is shared with other end if the system may be difficult to get through to the desired party at the other end if the system begins to overload or someone else is connected to the desired receiver of the data.

The drawbacks of the analog phone system are being overcome as new, digitally oriented links are installed by the various phone companies. Even without these digital links, the telephone system is powerful and popular vehicle for the transmission of data.

The simplified schematic of the standard telephone is that when the phone is not in use. Called “on-hook”, it looks like an open circuit, when the phone receiver is lifted from the cradle switch, the circuit to the local office is completed. A current of about 20 mA flows through this loop, from a battery at the phone office. The presence of this flow tells the office that the phone has gone off the hook.

A special internal transformer is used inside the phone to prevent the users’ voices from coming back too loudly to the ear. At the same time, this transformer passes a small amount of voice signal from the microphone element to the speaker so that users can hear themselves talking.

Any device that is connected to the phone line, either in place of a phone or alongside it, must meet strict standards to ensure the safety and reliability of the overall phone system.

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1000 LINE EPABX IN RDCIS SAIL, RANCHI

MAKE:Crompton Greaves

MODEL:NODEX- NE1200

SOFTWARE USED:OKI-JAPANPROCOMM – VERSION MT.2.4.3

Data Communication:

Electronically conveying information from a source to a destination over telephone line. It includes management and control of connections as well as the information transformer

Data Communication Network:

It include a combination of a transmission medium, a communication device on each end of the network and a method of translating the signals of the communication device to form a medium.

RJ11C or RJ11W Telephone Jack

RS232C Interface

RS232C Interface

Communication Software:

Since now-a-days computers are used in a network, so both modern and communication software should be present for interfacing the modem to computer. Phone

line

Computer Modem

Modem Computer

IBM PCXT, AT Equivalent

Communication Software

Modem

Telephone line

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Modem:A device which converts the digital signals from a computer or data communications terminal into analog signal suitable for transmission over phone lines. There are 2 types of modem which are connected from personal computer to phone lines.

1. Internal 2. External

Internal:

Modem plug directly into the personal computer.External:

Modem required a serial interface card within a personal computer to which modem is

connected.

Battery:The Battery used for the system or in telephone exchange has backup of 8-10 hours. It has a

specific gravity of about 1200 and is measured by hydrometer. According to the systematic

diagram battery has 24x2V and 600 AH.

FCBC:The full form of FCBC is Float –cum-boost charger. This converts AC to DC supply. Now after

this conversion the supply goes to the system. It is also helpful in charging the battery. The main

advantage using this FCBC is that when power failed then DC supply continues to flow through

the system.

Power Supply Unit (PSU):

Power Supply Section : 5V/30A, 12V/5A

: 12V/25A, 12V/83A

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Following Control cards are used in 1000 line EPABX Telephone Exchange

1. CPU - Central Processor Unit2. IOC - Input Out put Control3. MMo - Main Memory4. DTCO - Data Transfer Control Card5. TNS - Tones Sender Card6. SSC - System Supervisory Control Card7. TSW - Time Switch Card8. DKCO - Disk Control Card9. POW - Power Card10. HWIFC - Highway Interface Card11. SLIC - Subscriber Loop Interface Card

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Function of SLICA Card:

The interface circuit to the user’s phone is called a subscriber loop interface circuit (SLIC).

There is one SLIC required for every phone in the system.

The SLIC provides basic functions, called BORSHCT functions. BORSHT stands for;

a) B-Batteryb) O-Over-voltage Protectionc) R-Ringingd) S-Supervisione) H-Hybridf) C-Coderg) T-Test

Battery:

The phone requires some voltage to operate, only when it is off-hook.

This voltage is most commonly 48V DC in the united States.

Over-voltage Protection:

The SLIC Protect against electrical disturbance and lightning, so that phone lines and SLIC are

not damaged under any condition.

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Ringing:

The phone company office sends a special voltage to ring the phone. When the phone is picked-

up, the SLIC must detect this and disconnect the special ringing voltage.

Supervision:

SLIC monitoring the phone line to detect when it is picked-up by a coller who wishes to use the

phone. When a phone is picked-up, the local office must send out a dial tone, then wait for the

user to dial.

The SLIC must “Keep on ear” on the line to determine when the call is finished and the phone is

returned to the on-hook condition.

Hybrid:

Hybrid is able to 2W to 4W conversion and separate the signal coming from this phone and the

signal from the other phone into two separate groups.

Test:

SLIC provides special test tones and signals on the line, to check the quality of the wires and

their overall performance.

The SLIC must allow these test signals to go out to the phone and pass the resulting signal back

to the office.

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Function of SSC Card:

System Supervisory Control (SSC) cards provides following functions:-

Provides alarm indicationa) Maintenance data sending/receivingb) Loop interface data sending/receivingc) Connected to the Central Process Unit (CPU)d) Internal-Unit Connector(IUCO) e) Loop Interface Circuit (LIF) or Clock Rout Cross Circuit(CLKX)

BWTL (Both Way Trunk Line Card): This card is used for tie up with other telephone

exchange

ATT (Attendant Console Card): From this card attendant console board is connected for

transfer of incoming calls from outside to the EPABX number

MMIPC (Man Machine Interface PC): This PC connected with DTCO (Data Transfer

Control Card) for changing any data in system software

Working of Telephone

When a person speaks into a telephone, the sound waves created by his voice enter the mouthpiece. An electric current carries the sound to the telephone of the person he is talking to.A telephone has two main parts:

i) The transmitter andii) The receiver

The Transmitter:

The transmitter of a telephone serves as a sensitive “electric ear”. It lies behind the mouth piece

of the phone. Like the human ear, the transmitter has an 14 eardrum.

The eardrum of the telephone is a thin, round metal disk called diaphragm. When a person talks into the telephone, the sound waves strike the diaphragm and make it vibrate. The diaphragm vibrates at various speeds, depending on the vibrations in air pressure caused by the varying tones of the speaker’s voice.

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The Receiver:

The receiver serves an “Electric mouth”, “Vocal cords”. The vocal cards of the receiver are a

diaphragm.

Two magnets located at the edge of the diaphragm causes it to vibrate. One of the magnet is a permanent magnet that constantly holds the diaphragm close to it. The other magnet is an electromagnet. It consists of a piece of iron with a coil of wire wound around it.When an electric current passes through the coil, the iron core becomes magnetized. The diaphragm is pulled toward the iron core and away from the permanent magnet. The pull of the electromagnet varies between strong and weak, depending on the variation of current.Thus, the electromagnet controls the vibration of the diaphragm in the receiver.

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SPECIAL FEATURES OF RDCIS, SAIL TELEPHONE EXCHANGE

Following are the special features of 1000 line EPABX Telephone Exchange of RDCIS

i) Automatic Call Back:

when the called station is busy, this feature helps the user to get through as soon as the called

station becomes free

Procedure:

After dialing a number if the user hears the busy dial tone, then a special code no. is given and

wait for registration tone and put the handset on the cradle when the called station is free, the

user’s telephone will ring first. As he lifts the handset Ring back tone will be heard

ii) Call Forwarding:

User’s incoming call can be diverted to any other extension temporarily.

Procedure:

Lift the handset and dial the special code for call forwarding and dial the extension number,

where the user wants to divert his incoming call. In order to release the registration, dialing the

code and wait for few seconds for confirmation tone.

iii) Call forwarding Don’t Answer:

Unheard calls can be transferred to another extension number automatically after few rings on

the dialed extension number

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Procedure:

By lifting the handset and dialing the special code for call forwarding don’t answer registration

and then dialing the extension number where the user wants to receive his incoming call

iv) Call transfer:The receive call can be transferred to any other extension number in order to assist the

caller to get the desired person

Procedure:After receiving the call simply dial another extension number. Till the communication is

established the caller will be listening the wait music

v) Call Pick Up:If nearby extension number is ringing and hot being answered, one can pick up that call without moving from his placeProcedure:By lifting the handset and dialing the code for call pick up followed by extension number which is ringing. Then the caller will be connected

vi) Group Call Pick Up:Using this features of the exchange two or more numbers existing in the hall can be grouped together on the request of subscribers. User having this facility can pick up the call from any nearby telephone sets which have been grouped togetherProcedure:Call can be picked up from any extension number which have been grouped together by dialing the special code

vii) Party Conference:While in conversation the third party can be connected.Procedure:During the conversation dial the third party’s extension number. When the third party answers dial, then all the three parties will be in conversation. If the party doesn’t answer or is busy the user station can be revert to second party

viii) Connectivity to BSNL:The subscriber can be connected to BSNL by using this featureProcedure:For making DOT calls, lift the handset and dial the special code, wait for the DOT dial tone and then dial the desired DOT number. If it is busy tone then after a dialing code, dial another code for automatically to get back the DOT tone as soon as the line becomes free.

ix) Connectivity from BSNL:

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Using this features the subscriber from outside can be connected to the desired extension no. through operator sitting on the console board in EPABX telephone exchange.

Procedure:From the incoming calls from outside one can ring the DOT numbers. After dialing the no. user will be connected to the operator sitting on the console board in the EPABX exchange and through the operator’s help it will be connected to the desired extension number.

x) Simplified DID facility:By using this facility the caller from outside can be connected to the desired extension number without the help of operatorProcedure:The caller shall dial the BSNL number after one ring a tone will be heard which is similar to the busy tone then press the (*) star button.

xi) Dynamic Locking to “O” dial facility:This facility ensures unauthorized uses of ‘O’ dial facility of the userProcedure:

Dial special code for dynamic locking followed by four digit number and wait for confirmation tone. To open the lock dial again a code followed by four digit no. which has been registered and wait for confirmation tone.

xii) Operator’s Assistance:Assistance of operator can be provided from the telephone exchange for any clarifications

on incoming call or in searching anyone’s extension number

Procedure:

Lift the handset and dial a special code for operator’s assistance.

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INTRODUCTION

AUTOMATION SYSTEMS A process can be automated by breaking down it into a collection of sub process ,

breaking each sub process into a collection of steps , and using a machine or a group of machines to execute each individual steps at the right time for the right duration.

A process automation system can be defined as a set of rules that define a process in a language or format that is unambiguously understood by the men and machines responsible for executing the processes.

PLCs-PROGRAMMABLE LOGIC CONTROLLERIt is used to replace sequential relay-based circuits in a process automation setup.

The user feeds the PLC with a sequence of instructions or a program. This program resides in the PLC’s memory.

Owing to their easy availability, compact size and low cost, PLCs have gradually become the most used automation system in the industrial application.

They can also be defined as digital operating electronics apparatus, which uses programmable memory for the internal storage of instructions.

This is done by implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog I/O modules various types of machines or processes.

One PLC manufacturer define it as: “solid-state industrial control device which receives signals from the user supplied controlled devices, such as sensors and switches, implements them in a precise pattern.”

The ladder diagram based determines them application process stored in user memory, and provides outputs for control processes or user supplied devices, such as relays or motor starters.

Basically it is a solid state, programmable electrical/electronic interface that can manipulate, execute, and/or monitor, at very fast rate, the state of a process or communication system.

It operates on the basis of programmable data contained in an integral microprocessor based system.

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What Is Inside A PLC?

The Central Processing Unit, the CPU, contains an internal program that tells the PLC how to perform the following functions:

Execute the Control Instructions contained in the User's Programs. This program is stored in "nonvolatile" memory, meaning that the program will not be lost if power is removed

Communicate with other devices, which can include I/O Devices, Programming Devices, Networks, and even other PLCs.

Perform Housekeeping activities such as Communications, Internal Diagnostics, etc.

How Does A PLC Operate?

There are four basic steps in the operation of all PLCs; Input Scan, Program Scan, Output Scan, and Housekeeping. These steps continually take place in a repeating loop.

Four Steps In The PLC Operations

1.) Input Scan

Detects the state of all input devices that are connected to the PLC

2.) Program Scan

Executes the user created program logic

3.) Output Scan

Energizes or de-energize all output devices that are connected to the PLC.

4.) Housekeeping

This step includes communications with programming terminals,

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internal diagnostics, etc...

These steps are continually processed in a loop.

UNITY PRO M: SOFTWARE USED FOR DESIGNING PLC

Next the software program is scanned and each statement is checked to see if the next condition is met. If the conditions are met, the processor writes digital bit “1” into the output image table and the peripheral device is energized.

If the conditions are not met, the processors write a “0” into the output image table and a peripheral device remains deenergized.

A PLC interfaces numerous types of external electrical and electronic signals.

These signals can be AC or DC currents or voltages. It is important to have sufficient I/O

capability in your PLC system.

Its better to have more less than so that, when more I/O points are required at the future

time, its easier to write the existing spare I/O points into the software (since the hardware

is already there).

There is no harm to the operating system in having spare I/O points; the software can be

programmed to ignore them, and these points will have a negligible effect on the PLC’s

scan time.

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What Programming Language Is Used To Program A PLC?

While Ladder Logic is the most commonly used PLC programming language, it is not the only one. The following table lists of some of languages that are used to program a PLC.

There are five graphical or textual languages available in the UNITY PRO are used for programming Atrium , Premium and Quantum platforms .

Ladder Diagram (LD) --Traditional ladder logic is graphical programming language. Initially programmed with simple contacts that simulated the opening and closing of relays, Ladder Logic programming has been expanded to include such functions as counters, timers, shift registers, and math operations.

Function Block Diagram (FBD) - A graphical language for depicting signal and data flows through re-usable function blocks. FBD is very useful for expressing the interconnection of control system algorithms and logic

Structured Text (ST) – A high level text language that encourages structured programming. It has a language structure (syntax) that strongly resembles PASCAL and supports a wide range of standard functions and operators.

Instruction List (IL): A low level “assembler like” language that is based on similar instructions list languages found in a wide range of today’s PLCs.

Sequential Function Chart (SFC) A method of programming complex control systems at a more highly structured level. A SFC program is an overview of the control system, in which the basic building blocks are entire program files. Each program file is created using one of the other types of programming languages. The SFC approach coordinates large, complicated programming tasks into smaller, more manageable tasks.

MANUAL OPERATION vs. AUTOMATED SYSTEMS

As the process becomes complex, the automation industries saw the advent of electromechanical devices.

The manufacturing process was broken down into small sub systems, and each one was controlled by a set of dedicated small controllers.

But these electromechanical components have a high failure rate; these caused control systems failures to be very often.

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Manual Operation Automated System

An individual switch for every step in the process

A single switch or minimal switches to operate the entire process

An army of operators fully involved in the process of manufacture

Very few operators, mainly performing process-monitoring tasks

Ample scope for negligence and human error

Minimization of human error

May be cost-effective only in very small setups

May be uneconomical for very small installations

Requires synchronization of many people, which may be difficult, if not impossible

Automatic synchronization between different constituent units and processes

Low and unpredictable production throughput

High and consistent production throughput

Poor, unpredictable, and not readily known capacity utilization

Better capacity utilization that can be calculated and predicted instantly

Efficiency of operation dependant highly on individual skills which may vary widely from operator to operator

Efficiency of operation not too dependant on operator skill as process is more or less automated

Poorer throughput after process changes if the operators are not used to the new process

Process changes easy to perform with minimal effect on throughput

Sensors

Sensors are, as the name indicates, the sense organs of the system. They are the eyes, ears, and nose of any automation system. Sensors are classified based on the kind of signal they sense.

From this point of view, they may be classified as:

Electrical sensors: Sensors quantifying and detecting electrical properties such as voltage, current, and charge

Magnetic sensors: Sensors signaling changes in magnetic field intensity or flux density

Optical sensors: Sensors used to detect or quantify light or other electromagnetic waves

Thermal sensors: Sensors detecting temperature, heat flux, or heat flow

Mechanical sensors: Sensors detecting force, pressure, velocity, acceleration, and position

Chemical sensors: Sensors giving information about the rate of a chemical reaction, radical or ion concentration, or chemical composition

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Controllers

A controller is an electronic device that, when triggered by a sensor, energizes an output in a desired manner. A single sensor or a group of sensors can trigger controllers. Likewise, controllers can have a single output or a group of outputs, which is altered on receipt of the right type of trigger.Controllers are of the following two types:

Hardwired controller: Consists of electrical, electronic, and electromechanical sub-assemblies such as timers, sequencers, and digital flip flops linked by wires to perform the desired control action

Programmable controller: Consists of a microcomputer with input ports, output ports, memory, a suitable operating system, and provisions to enter and execute programs to achieve the desired objective

Actuators

Actuators are like the limbs of an automation system. When triggered, they respond by producing physical movements. Actuators can be classified into three types on the basis of the type of energy required. The three types are:

Electrical: The prime moving force is electrical in nature. Examples of this type of actuators are electrical solenoid valves, stepper motors, and close loop position servos.

Hydraulic: These actuators work on hydraulic (liquid pressure) principles. Hydraulic actuators have a set of valves and an arrangement to pump liquid at high pressure. By operating a set of valves, liquid is pumped into the actuator producing movement for a specific purpose. Usually, another set of valves releases the liquid when the actuator returns to ‘home’ position.

Pneumatic: Pneumatic actuators work on gas pressure. These are very similar to hydraulic actuators, but the medium employed is gas.

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Actuators can also be classified on the basis of the type of movement they produce. Based on this classification, there are two types of actuators:

Linear: The movements produced have constant linear velocity.

Rotary: The movements produced have constant angular velocity

Hardware Components of a PLC

PLCs are digital electronic devices that use a programmable memory that coordinates input and output (I/O) modules to control processes.

A PLC has the following main hardware components:

A processor

Power supply

A rack

Input/Output modules

Block Diagram of the Standard Components of a PLC

Processor Module

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The processor or the Central Processing Unit (CPU) is a part of the PLC that executes the control program stored in the PLC memory.

The processor controls the data exchange between the input and output modules.

In essence, the CPU is the ‘brain’ of a programmable controller.

The function of the processor is similar to a computer.

The only difference is that in a processor, special programs and instructions are used to perform the operation desired from the PLC.

The General Architecture Of a CPU :

C PU m odule

R AMProgram m em ory

Tim ersC ounters

F lagsProcess im ages

System data

R O M(O perating system )

Arithm etic unitAC C U M and R LO

M em orysubm odule

Seria l in terface

M icroprocessor

D ig ita l m odulesinput/ output

Inte lligent m odulesinput/ output/ com m unication

Analog m odulesinput/ cutput

I/O M odules

Figure 2.2: Architecture of a CPU

Power Supply

The power supply unit is another main hardware component of a PLC system. The power supply provides power for operating PLC. PLCs have two types of power supplies:

CPU power supply: This power supply is normally a dedicated power supply to power the processor module (the CPU) and other modules. This power supply module generates internal voltages from the mains supply of 120V AC or 230V AC. Normally, the

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operating voltage of a CPU and other modules is 5V DC. In most PLCs, a battery backup is also provided. This prevents the program being erased from the RAM, which is the volatile memory, in the event of normal supply failure.

Load power supply: This gives AC or DC power supply to the channels of the I/O modules that are inserted in the rack. This supply is used for interrogating the input channels in the input modules and energizing the output channels.

Rack

The chassis or rack is a framework with or without slots into which the I/O modules are inserted. The rack may be a simple dual-in-line rail (more commonly known as DIN Rail) on which the modules are mounted and the connections are made through separate connectors or perhaps, more commonly, a backplane connector with slots for inserting modules.

the arrangement of the modules in a PLC rack :

Physical Layout of a PLC Rack

Input/Output Modules

In order to carry out any operation, the processor must interpret the status of the input field devices and give commands that can be interpreted correctly by the output field devices.

The I/O modules convert the signals received from input field devices into a processor-compatible format and similarly convert signals from the processor to the field output devices.

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The I/O modules are provided with terminals for connecting field devices.

When installed, the I/O modules are wired to field devices on one side and connected to the slot in the rack on the other side.

When connected this way, the rack and I/O module combination is called the I/O system which forms an interface between the processor and the field devices.

The rack and I/O modules are either fixed or modular in design.

Methods of Programming

In the case of PLCs, machine language and symbolic programming is used. As explained above, writing a program using machine codes is very cumbersome and hence symbolic representation of a program is more readily understood by operators and programmers.

There are normally three methods of representation in symbolic programming:

Ladder diagram

Control system flowchart

Statement list

Ladder Diagram

This method is a graphical representation of the problem using relay logic. When PLCs were first developed, one of the primary intentions was to have its programming language similar to that used in relay systems, which PLCs were to replace. This allowed for easier use of PLCs in relay replacement applications by users already familiar with ladder diagrams. This is by far the most popular method of programming because of its similarity to hardwired systems instead of the English language-like syntax of most computer programming languages. The symbols represent scans for the signal states, ‘0’ and ‘1’. On the screen, they are arranged in the form of horizontal rungs, which gives the appearance of a schematic circuit diagram.

Control System Flowchart

This method is again a graphical representation of the control task, but the symbols used here are different. Here, each individual function is represented by a symbol. The input is shown on the left of the symbol and the output on its right. This method is not very popular.

Statement List

This method uses mnemonic abbreviations to represent a control task. The syntax in this method is more similar to that of assembly languages.

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DIFFERENT METHODES OF PLC PROGRAMMING:

Different Methods of PLC Programming

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LEARNING OUTCOMES & ANALYSIS

Working with STEEL AUTHORITY OF INDIA LIMITED (SAIL) as a summer training was a very nice experience. I learnt a lot about designing basic systems in electrical and how the importance of electrical power tools, hardware and software, in any project. I also practiced what I learnt in the university and applied it on field. Working with Electronics department enhanced my major understanding .In addition, I gained a good experience in term of self confidence, real life working situation, interactions among people in the same field and working with others with different professional background. I had an interest in understanding basic engineering work and practicing what has been learnt in the class. Also, the training was an opportunity for me to increase my human relation both socially and professionally.

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CONCLUSION

The profit of an organization entirely depends on the way the top chairs manage theresources the organization has. Whatever the other aspects may be, it was seen thatmanaging human resource was extremely difficult. The stability or the sustainability of theorganization mostly depends on this factor.On the other hand, it was prominently seen that thinking should precede doing. In most casesit could be seen that there exists easier or better ways to do something.As far as the above mentioned factor is considered, continuous knowledge mining followedby experience in a cycle upholds the entire system in every aspect.Earning and living a satisfactory life is the desire of all.

SUGGESTIONS FOR THE IMPROVEMENT OF THEENGINEERING WORKSHOPS

The experiences I had in the Engineering Workshops suggest me the following to beimplemented for the improvement of the place.1. Maintain a simple booklet on materials that are used in the Engineering Workshops.This should contain the properties and the processing aspects (cutting speeds,coolants, etc.)2. Maintain a booklet on each machine about the capabilities of them and the currentcondition.3. Implement a method to return the unused consumable goods to the stores.4. Maintain a training program for the employees at least one session a month.5. Teach the employees how to collaborate with others.

SUGGESTIONS FOR THE IMPROVEMENT OF TRAININGPROGRAM

A group of 14 undergraduates including myself had the first year in-plant training at theFaculty Workshop together and all of us did what we were supposed to do separately.Though we discussed what we were doing among ourselves a little, I feel it would have beenbetter if we were explicitly encouraged by the Industrial Training Unit to had formaldiscussions at least once a week. Some of the undergraduates (I feel I was one of thatgroup) were seen to work harder gaining more knowledge and the real taste of engineeringand some were not. If discussions of this nature were conducted, all of us could have gaineda better knowledge and improved ourselves collectively. The participation of the trainingsupervisor would have been a further encourage.Furthermore I suggest that it would have been better if all the undergraduates were exposed

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to some presentations on the in-plant training before we were released. Some illustrative

aspects of practical engineering could have been discussed widening the openness of theeyes of us. Though we new what engineering was, we were not exposed to any sort ofpractical engineering when we went for the training

FUTURE SCOPE OF THIS TYPE TRAINING

Future Automation Technologies is one among the leading total welding automation solutions provider and manufacturer in India for manufacturing and supplying of automated welding special purpose machines (SPM) for automobile industries, heavy engineering industries, valve industries, pump industries, scaffolding industries and allied industries.

Vision:

To enhance customer satisfaction and our brand image domestically & globally and achive exponential growth to leadership through higher technology products and services.

Mission:

To deliver greater value to our customers by providing Complete Technical & Economical Solutions through technical leadership,innovations and manufacturing excellence that is responsive to dynamic market needs.

New technology direction :

Industrial automation can and will generate explosive growth with technology related to new inflection points: nanotechnology and nanoscale assembly systems; MEMS and nanotech sensors (tiny, low-power, low-cost sensors) which can measure everything and anything; and the pervasive Internet, machine to machine (M2M) networking.

Real-time systems will give way to complex adaptive systems and multi-processing. The future belongs to nanotech, wireless everything, and complex adaptive systems.

Major new software applications will be in wireless sensors and distributed peer-to-peer networks – tiny operating systems in wireless sensor nodes, and the software that allows nodes to communicate with each other as a larger complex adaptive system. That is the wave of the future

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CERTIFICATE

This is to certify that the following report is based on the work done by pankaj

sahu(reg no 10907659) student of B.tech (Electronics and communication ), of Lovely

professional university phagwara (Punjab) during his stay at RDCIS, SAIL, Ranchi as

Vocational Trainee during 02/06/2012 to 15/07/2012.

AGM & PROJECT CO-ORDINATOR Power & Control Group

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REPORTON

IN-PLANT TRAININGAT

RESEARCH & DEVELOPMENT CENTRE FOR IRON & STEEL,STEEL AUTHORITY OF INDIA LIMITED

RANCHI – 834002

SUBMITTED BY:

Pankaj sahu

(THIRD YEAR, Electronics and Communication Engineering.)

Lovely Professional University Phagwara (Punjab)

RANCHI JUNE -JULY, 2012