Process explanation 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 BLOCK DIAGRAM
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 processis to applyPLCto designautomaticbatchingsystemandall
objectivesinthisprojectwere successfullydone asplanned.