Hyperglass Cleaning Project 1. Functional Design Specification of Hyperglass Cleaning is done. 2. Work Progress Report is shown which has Bill Of materials as well. 3.Autocad Design of whole process is Made. (Process Model, Power supply connections, PLC model, DI/Do module) 4.Ladder Logic design and SCADA design is also enclosed. 5. I/O mapping is done.

1. FUNCTIONAL DESIGN SPECIFICATION
Of
HYPERGLASS CLEANER
By
Shweton Kedia

2. TABLE OF CONTENTS
1. INTRODUCTION
 OVERVIEW
 PROBLEM STATEMENT
 PROJECT OBJECTIVE
2. PROCESS
3. FUNCTIONAL BLOCKDIAGRAM
4. COMPONENTS USED
5. HARDWAREREQUIREMENT
6. SOFTWAREREQUIREMENT
7. CONCLUSION

3. INTRODUCTION
OVERVIEW
The use of control systems to control the machines and processes, reducing the need for
human intervention, thus making the production rate constant and almost error free is
Industrial Automation.
In the past humans were the main method for controlling a system. More recently electricity
has been used for control and early electrical control was based on relays. The development of
low-cost computer has brought the most recent revolution, the Programmable Logic Controller
(PLC). The advent of the PLC began in the 1970s, and has become the most common choice for
manufacturing controls.
Some advantages of PLC are:
 Flexibility: One single Programmable Logic Controller can easily run many machines.
 Correcting Errors: In old days, with wired relay-type panels, any program alterations
required time for rewiring of panels and devices. With PLC control any change in circuit
design or sequence is as simple as retyping the logic. Correcting errors in PLC is
extremely short and cost effective.
 Space Efficient: Today's Programmable Logic Control memory is getting bigger and
bigger this means that we can generate more and more contacts, coils, timers,
sequencers, counters and so on. We can have thousands of contact timers and
counters in a single PLC. Imagine what it would be like to have so many things in one
panel.
 Low Cost: Prices of Programmable Logic Controllers vary from few hundreds to few
thousands. This is nothing compared to the prices of the contact and coils and timers that
you would pay to match the same things. Add to that the installation cost, the shipping
cost and so on.
 Testing: A Programmable Logic Control program can be tested and evaluated in a lab.
The program can be tested, validated and corrected saving very valuable time.
 Visual observation: When running a PLC program, a visual operation can be seen on
the screen. Hence troubleshooting a circuit is really quick, easy and simple.
A PLC works by continually scanning a program. We can think of this as scan cycle which
consist of 3 important steps.
The steps are reading the input, execution of logic, and giving the output.
There are typically more than 3 but we can focus on the important parts and not worry
about the others.
Typically, the others are checking the system and updating the current internal counter
and timer values.

4. Input Scan- The status of external inputs is written to the internal input image table.
Execute program- Each ladder rung is scanned and solved using the date in the input file. The
resulting logic is written to the output image table.
Output Scan- The output image data is transferred to the external output circuits, turning the
output device ON or OFF.
Input/output Module Checks- Internal check on memory, speed and operation.
This project is based on the water purification. To make water more acceptable for a desired
end-use. These can include use for drinking water, industry, medical and many other uses.
So, there are 3 ingredients water and other two ingredients are added in specified time to the
mixing tank. After all the ingredients have been added to the mixing tank, the mixture is
PLC SCAN
CYCLE
Batching
System

5. blended by running the agitator for a given time. When the blending time is complete, the
finished product is pumped to the filling lines.
There are eight limit switches which have been implemented in this project. There are four
calibrated motorized control valves in this project, which are used to control the fluids flow,
three pumps to deliver the fluids inward and outward the mixer tank and Agitator to make the
mixer tank blending for a given time.
The main goal of this project is to install a new automated batching system for mixing the Hyper
Glass Cleaner.
PROBLEM STATEMENT
Initially Manual Control System was implemented to control the system.
When using manual control system, there were some issues with which we were confronted
such as the production, safety, energy consumption and usage of raw material are all subject to
the correctness and accuracy of human action. It’s very likely human errors affect quality of the
final product.
So, it was important to install a new automated batching system.
PROJECT OBJECTIVE
The main objective of this project is to apply PLC to design automatic batching system.
Some goals need to be achieved are below:
 To design a closed-loop system which can be used to control the adding and
mixing of the ingredients which are used properly.
 To make sure that motorized control valves does open at the right time to
ensure delivery of the ingredients to the mixer in the appropriate ratio.
 Limit switches are inside the valves which ensure that the valves do opens or
closes.
 To maintain an automatic and continuous flowrate into the filling lines.
To ensure the objective to be completed, hardware components such as PLC (), limit switches,
valve, pumps and agitator will be used to build the Automatic batching system. Software
programs such as (RsLogix5000) will be used to write a program (ladder diagram) to direct and
control the system and SCADA software by using Factory Talk View Studio.

6. PROCESS
There are 5 steps in the Batching process:
1. Add City Water to Mixing Tank
2. Add Ingredient QR to Mixing Tank
3. Add Ingredient KM to Mixing Tank
4. Mix the batch in Mixing Tank
5. Pump the batch to the filling lines from the Mixing Tank.
Valves:
AV-CW: Supplies city water to the mixing tank.
AV-QR: Supplies QR ingredient to the mixing tank.
AV-KM: Supplies KM ingredient to the mixing tank.
AV-MT: Supplies the finished product to the filling lines.
Limit Switches:
LS-CW1: Indicates when valve AV-CW is closed.
LS-CW2: Indicates when valve AV-CW is open.
LS-QR1: Indicates when valve AV-QR is closed.
LS-QR2: Indicates when valve AV-QR is open.
LS-KM1: Indicates when valve AV-KM is closed.
LS-KM2: Indicates when valve AV-KM is open.
LS-MT1: Indicates when valve AV-MT is closed.
LS-MT2: Indicates when valve AV-MT is open.
Pumps:
Pump-QR: Pumps ingredient QR to the mixing tank.
Pump-KM: Pumps ingredient KM to the mixing tank.
Pump-MT: Pumps ingredient MT from the mixing tank.

7. Motor: Agitator MTR-MTA: Blends the ingredient in the mixing tank.
Operator Panel Component: -
1) System ready light PL1: Indicates the system is ready for Batch.
2) System fault pilot light PL2: Indicates the system has a fault
3) Start batch pushbutton switch PB1: Start a new batch.
4) Start batch pushbutton switch PB1: Start a new batch.
5) Stop batch pushbutton switch PB2: Stop the batching process.
6) Adding water light PL3: Indicates adding water to the mixing tank.
7) Adding QR light PL4: Indicates adding QR to the mixing tank.
8) Adding KM light PL5: Indicates adding KM to the mixing tank.
9) Blending pilot light PL6: Indicates blending the ingredients.
10) Pumping to lines light PL7: Indicates pumping the ingredients.
11) E-stop Pushbutton PB3: Immediately stops the entire system
To begin a new batch, the operator will verify that the “SYSTEM READY” pilot light is on and
that the Mixing Tank is ready to receive ingredients.
The operator will then press the “START BATCH” pushbutton to begin the batching process. The
“SYSTEM READY” pilot light will turn off. No further operator input is required.
Step 1 – City Water
Automatic valve AV-CW will open. The “ADDING WATER” pilot light will illuminate.
Valve AV-CW will remain open until 700 litres of City Water is in the Mixing Tank after which
the Valve AV-CV will close.
The state of AV-CW will be verified by limit switch LS-CW2. If LS-CW2 is not made within 2
seconds after the valve was told to open, a fault will be generated and the system will shut
down. The pilot light “SYSTEM FAULT” PL2 will illuminate indicating that a fault has occurred.
LS-CW1 will verify that the valve is closed within 2 seconds after the valve was told to close. If
the valve closure is not verified within 2 seconds, a fault will be generated, the system will shut
down and PL2 will illuminate.

8. All valves and their respective limit switches will work in the manner described above.
After the City Water has been added, valve AV-CW will close and the “ADDING WATER” pilot
light will turn off.
Step 2 – Ingredient QR
Valve AV-QR will be opened. After the valve position has been verified by LS-QR2, PUMP-QR
will pump 162 litres of ingredient QR into the Mixing Tank. The “ADDING QR” pilot light will be
illuminated while the pump is running.
After the ingredient QR has been added to the Mixing Tank, PUMP-QR stops and the “ADDING
QR” pilot light will turn off. Valve AV-QR will close.
Step 3 – Ingredient KM
Valve AV-KM will be opened. After the valve position has been verified by LS-KM2, PUMP-KM
will pump 132 litres of ingredient KM into the mixing tank. The “ADDING KM” pilot light will be
illuminated while the pump is running.
After the ingredient KM has been added to the Mixing Tank, valve AV-KM will close. PUMP-KM
will stop. The “ADDING KM” pilot light will turn off.
After LS-KM1 indicates the valve has been closed, the agitator motor MTR-MTA will start. The
“BLENDING” pilot light will illuminate.
Step 4 – Mixing
The agitator will run for 3 minutes. The “BLENDING” pilot light will illuminate.
After the agitator is finished, the “BLENDING” pilot light will turn off.
Step 5 – Pump to filling lines
Valve AV-MT will open. After LS-MT1 indicates the valve is open, the “PUMPING TO LINES” pilot
light will illuminate.
PUMP-MT will pump the entire batch to the filling lines. When the Ultrasonic Level Sensor ULS-
1 indicates that the tank is empty, PUMP-MT will turn off, valve AV-MT will close and the
batching cycle is complete.
The “PUMPING TO LINES” pilot light will turn off and the “SYSTEM READY” pilot light will
illuminate.

9. During every phase of the batching process, the liquid level must be monitored by the PLC. If
the level rises to greater than 95% of that Mixing tank’s capacity, the system will generate a
fault and the batching process must be halted.
The operator may press the “STOP” pushbutton PB3 to stop the process at any time.
Fig.- Automatic Batching Systemof Hyper glass cleaning

10. FUNCTIONAL BODY DIAGRAM
Check for all the LS1 of all 4 valves if
they are high.
Start
Check for all valves and pumps
close/off.
Check for Tank QR and KM full and
Tank MT empty.
Check if City water ready?
PL1=ON, Rest of the light should be
OFF.
No
Process not
ready
No
No
No
No
Adding CW to MT begins. PL3 On
AV-CW=open, LS-CW1=low, LS-
CW2=high
CW flowingto MT stops after 700
litres is filled by usinglevel sensor.
PL3 off.
Y
Y
Y
Y
Y
FaultNo
Y
1

11. 1
Pump QR On. PL4 On
AV-QR=open, LS-QR1=low, LS-
QR2=high
QR flowingto MT stops after 162
litres is filled by usinglevel sensor.
PL4 off.
Y
AV-CW=close, LS-CW1=high, LS-
CW2=low
Fault
No
AV-QR=close, LS-QR1=high, LS-
QR2=low
Pump KM On. PL5 On
AV-KM=open, LS-KM1=low, LS-
KM2=high
No
Fault
KM flowingto MT stops after 132
litres is filled by usinglevel sensor.
PL5 off.
AV-KM=close, LS-KM1=high, LS-
KM2=low
Blending in MT tank begins. PL6 On
Y
Y
Y
No
Fault
FaultNo
Agitator motor runs for 3 minutes
and stops. PL6 Off
2
No
Fault

12. 2
Pump MT ON. Supply to filling line
starts. PL7 starts.
AV-MT=open, LS-MT1=low, LS-
MT2=high
No
Fault
Y
AV-MT=open till MT tank empties.
If tank empty. AV-MT=close. LS-
MT1=high, LS-MT2=low. PL7 Off
Process to be ready for new batch.

13. COMPONENTS USED
1. Sensors
Autonix M18 Capacitive ProximitySensorsforlevelmeasurements.
2. Motorized Control valves
3. Pumps
Kirloskar2HP,1.4KW pump. KDS225++ (3pcs)
4. Contactors
SchneiderLC1D09, 9A (3 pieces)
Siemens45A,3TF4602-0AP0 (1PC)
5. Thermal Overload Relay
SchneiderLRE16, 9-13A (3pieces)
Siemens32-50A,3UA5800-2F21 (1PC)
6. Agitator
SS Noble CustomAgitatorformixing,upto25HP.
7. Other Accessories
Pushbutton(3pcs)
PilotLight(7 pcs)
Control Panel Cabinet
LED
FAN
DIN rail.

14. HARDWARE REQUIREMENT
1. PLC
CompactLogix 5370, L16ER.
2. Communicating Protocol
EthernetCable,RJ45
SOFTWARE REQUIREMENT
1. Rslogix 5000(on Simulator),Studio5000 (For Live working)
2. RSLINXCLASSIC
3. Studio5000 Logix Emulate (if onSimulator)
4. FACTORYTALK VIEW SCADA
CONCLUSION
 An AutomaticBatchingSystemusingProgrammable LogicControllerhasbeensuccessfully
designedandsimulatedbyapplyingall the conceptof control systematthisproject.
 The systemthatisproducedcan be modifiedtobe betterif some of the electrical devicesand
systemare upgradedandimproved.
 The theoryand conceptof the automaticbatchingsystemisbasedonthe control system.In
programmingdesign,understandingsof the desiredcontrol systemandhow touse the Ladder
Diagram totranslate the machine sequence of operationare the mostimportantparts,because
it haSdirecteffectonthe systemperformance.
 The main aiminthis processisto applyPLCto designautomaticbatchingsystemandall
objectivesinthisprojectwere successfullydone asplanned.

15. Work Order
Ordered by: Sage Automation
OrderDate:7-01-2020 Delivery Date: 20-01-2020
Client Name: Shweton Kedia Duration of Project:100 hr
Contact Information:
Address: Email-
Id:skedia2014@gmail.com
Sage Automation, Thane
Ph. No: +91-9591371457
Project Name: HYPERGLASS CLEANING
MANUFACTURER ALLEN BRADLEY
MODULE CompactLogix
L16ER
SOFTWARE RSLOGIX 5000
SCADA SOFTWARE FACTORY TALK VIEW STUDIO
PLC DETAILS
Work to be completed
 HARDWARE
CONFIGURATION
 AUTOCAD DESIGNING
 LOGIC DEVELOPMENT
 PLC PROGRAMMING

16.  LOGIC SIMULATION
BILL OF MATERIALS
DESCRIPTION ITEM COST QUANTITY TOTAL COST
1. Push buttons(Start,stop) 80 2 160
2. Emergency Pushbutton 160 1 180
3. Plastic Pilot Light on Panel 50 7 350
4. DIN rail 35mm lenght 48 24 1152
5. Elite Mild Steel Control Panel
Cabinet IP33
15000 1 15000
6. Autonix M18 Capacitive
Proximity Sensor
900 3 2700
7. Kirloskar 2HP,3P pump, KDS-
225++ 5.3L/s, 3000RPM,1.4KW
12819 3 38457
8. SS Noble Custom Agitator
For mixing the mixture in the
final tank. Upto 25HP motor.
80000 1 80000
9. Schneider Contactor LC1D09, 9A
10. Schneider Thermal Overload
Relay, LRE16, 9-13A
876
1300
3
3
2628
3900
11. Siemens 45A Contactor,
3TF4602-0AP0
6930 1 6930
12. Siemens 32-50A Thermal
Overload Relay, 3UA5800-2F21
3000 1 3000
13. Motorized Control Valve 8000 4 24000
14. PLC – Allen bradley
CompactLogix L16ER
130000 1 130000
15. RsLogix5000 Mini edition 68000 1 68000
16. Rslinx Classic 69000
17. Factory Talk View Studio – SCADA 18000
18. LED 180
19. Fan 150
1 69000
1 18000
1 180
1 150
Total- 4,63,787 rupees

17. AUTTOCAD DESIGN OF
HYPERGLASS
CLEANING PROJECT
BY-SHWETON KEDIA

18. PROCESS MODEL OF HYPERGLASS CLEANING

19. 415 V Supply to different Motors
General Appearance of Control Panel of Hyperglass Cleaner

20. Front View of Control Panel

21. Interior View of Control Panel
SMPS Connection

22. ALLEN BRADLEY COMPACT LOGIX PLC
MODEL L16ER

23. PLC I/O Connections
DI Module Connections

24. DO Module Connections

31. IO MAPPING
Sr.
No.
DESCRIPTION SIGNAL BINARY BIT
1 Emergency_button DI SS_Emergency_button
2 START DI SS_START
3 Stop DI SS_Stop
4 PR_Sensor1 DI SS_PR_Sensor1
5 PR_Sensor2 DI SS_PR_Sensor2
6 PR_Sensor3 DI SS_PR_Sensor3
7 PR_Sensor4 DI SS_PR_Sensor4
8 LS1_CW DI SS_LS1_CW
9 LS2_CW DI SS_LS2_CW
10 LS1_QR DI SS_LS1_QR
11 LS2_QR DI SS_LS2_QR
12 LS1_KM DI SS_LS1_KM
13 LS2_KM DI SS_LS2_KM
14 LS1_MT DI SS_LS1_MT
15 LS2_MT DI SS_LS2_MT
16 PL1-System ready DO SS_PL1-System ready
17 PL2-Fault_system DO SS_PL2-Fault_system
18 PL3-Adding CW DO SS_PL3-Adding CW
19 PL4-Adding QR DO SS_PL4-Adding QR
20 PL5-Adding KM DO SS_PL5-Adding KM
21 PL6-Agitator On DO SS_PL6-Agitator On
22 PL7-To supply lines DO SS_PL7-To supply
lines
23 Pump_QR DO SS_Pump_QR
24 Pump_KM DO SS_Pump_KM
25 Pump_MT DO SS_Pump_MT
26 AG_On DO SS_AG_On