This document describes a thesis project on implementing an automated PLC-based control system in a cement plant. The project involves developing motor block and group control block logic in Siemens Step 7 software to control crushers via a Siemens PLC and Expert Control System SCADA. Methodology includes defining inputs and outputs for motor and group blocks, designing submodules for start/stop, inputs, and outputs, and combining submodules into faceplates. The automated system is intended to reduce labor costs and improve performance by remotely monitoring and controlling plant operations.

1. PLC BASED AUTOMATED
SYSTEM IN PROCESS INDUSTRY
(CEMENT PLANT)
NAME: SHAHID FAIZEE
COLLEGE: MANIPAL INSTITUTE OF TECHNOLOGY
REGISTRATION NO.: 080929282
ROLL NO.: 57
YEAR: IV (8th Semester)
A thesis presentation presented in partial fulfillment of the
requirements for the degree of
Bachelor of Engineering
in
Mechatronics

2. LIST OF CONTENTS
TOPICS COVERED SLIDE NUMBER
INTRODUCTION 5
LITERATURE
REVIEW/BACKGROUND THEORY 15
IMPORTANCE OF THE PROJECT 20
OBJECTIVES OF THE PROJECT 22
METHODOLOGY 25
RESULTS OBTAINED 53
FINAL CONCLUSION 56
FUTURE SCOPE OF THE PROJECT 59
REFERENCES 60
2

3. LIST OF FIGURES
3
FIGURE NO. FIGURE TITLE SLIDE NUMBER
FIGURE 1 Components of a PLC Hardware 6
FIGURE 2 A schematic View of SCADAArchitecture 10
FIGURE 3 A Schematic Representation of Working of SCADA 11
FIGURE 4 Profibus Cable 14
FIGURE 5 Screenshot of SIEMENS SEMATIC MANAGER STEP 7 (S7)
Software
17
FIGURE 6 Screenshot of SIEMENS LAD/STL/FBD (FB1) STEP 7 Software 18
FIGURE 7 Screenshot of SIEMENS LAD/STL/FBD (FB2) STEP 7 Software 19
FIGURE 8 A Pictorial View of SCADA (ECS) SOFTWARE in Control
System Lab
21
FIGURE 9 Limestone Crushing Process 23
FIGURE 10 Motor Block Diagram 30
FIGURE 11 Group Control Block Diagram 35

4. 4
FIGURE NO. FIGURE TITLE SLIDE NUMBER
FIGURE 12 Screenshot showing Submod for Start and Stop (Auto and Local
Mode)
42
FIGURE 13 Screenshot showing Submod for Inputs 43
FIGURE 14 Screenshot showing Submod for Outputs of Motor Block 44
FIGURE 15 Screenshot showing Submod for Start and Stop (Auto and Local
Mode)
45
FIGURE 16 Screenshot showing Submod for Inputs 46
FIGURE 17 Screenshot showing Submod for Outputs 47
FIGURE 18 Screenshot showing the Faceplate of a Motor Block (Combination
of three Submods of Motor Block)
48
FIGURE 19 Screenshot showing the Faceplate of a Group Control Block
(Combination of three Submods of Group Control Block)
49
FIGURE 20 A Typical Layout for Crusher in Cement Plant (Run-Time Mode) 50
FIGURE 21 Graphical Interpretation by Expert Control System (ECS) SCADA
through Human Machine Interface (HMI)
53
LIST OF FIGURES

5. INTRODUCTION
 This Project deals with controlling a unidirectional motor for
crusher section of a cement plant using a PLC controller
hardware such as Siemens or ABB or Rockwell. In this project
Siemens PLC is used.
 PLC Hardware is nothing but an industrial computer used to
monitor inputs, and depending upon their state makes decision
based on its program or Logic to control (turn on/off) its output to
automate a machine or a process.
 The PLC will then be integrated with SCADA.
5

6. POWER SUPPLY SIEMENS (S7) PLC
PROCESSOR
ETHERNET
MODULE
PROFIBUS
MODULE
INTRODUCTION
PROFIBUS interface
(9-pin D-sub female
connector)
Components of a PLC Hardware
FIGURE 1
6

7.  SCADA (SUPERVIOSRY CONTROL AND DATA
ACCQUISATION) is a system used to monitor a plant from a
central location. It is widely used in process and factory industry.
 The Application of PLC and SCADA in Cement Manufacturing
Industry is very vast.
 SCADA used is Expert Control System (ECS) which is a product of
FlSmidth Private Limited.
INTRODUCTION
7

8. Project compose of three main Components :
 PLC (Programmable Logic Controller)
 HMI (Human-Machine Interface) /SCADA
 Communications
INTRODUCTION
8

9. COMPONENTS OF PROJECT
 PLC – The function of an PLC is to collect the onsite information
and this information is sent to a central location with the help of the
communication element.
 HMI/SCADA – The function of HMI/SCADA is to display the
information received in an easy to understand graphical way and
also to archive all the data received.
 COMMUNICATION – It happens through various means. It
happens via data cable within a plant or through a fiber optic or via
radio between different region.
INTRODUCTION
9

10. PROJECT ARCHITECTURE
INTRODUCTION
FIGURE 2
PROJECT Architecture
10
PC
PLC
I/O I/O I/O I/O
Ethernet
Profibus
Profibus Profibus Profibus

11. SCADA SUPPLIERS
1. FLSMIDTH ECS (Expert Control System)
2. SIEMENS SIMATIC WinCC
3. INVENSYS Intouch Wondercare
4. ROCKWELL RSView
5. ABB EMS
6. Schneider Electric Vijeo Citec
INTRODUCTION
11

12.  COMMUNICATION PROTOCOLS
 PROFIBUS
 MODBUS
 CONTROLNET
 DEVICENET
 In this project PROFIBUS Protocol is used.
INTRODUCTION
12

13.  PROFIBUS – It is used in large devices such as PCs and PLCs to
talk with multiple smaller devices like sensors, drives, valves, etc. It
uses RS-485 for transmission of data. Profibus also uses a
master/slave configuration for communication. Supports upto 126
devices.
Profibus Cable
INTRODUCTION
FIGURE 4
13

14.  PLC SIEMENS STEP7 (S7) SIMATIC MANAGER
SOFTWARE
STEP 7 is the basic programming and configuration software for
SIMATIC. It is made up of a series of applications, each of which
does a specific job within the scope of programming an
automation task, such as:
 Configuring and assigning parameters to the hardware
 Creating and debugging user programs
 Configuring networks and connections
 The basic package can be extended by a range of optional
packages, for example, additional programming language
packages such as SCL, S7 Graph, or HiGraph.
LITERATURE REVIEW
14

15. Background Theory and Automation Technology
 In the absence of process automation, plant operators have to physically
monitor performance values and the quality of outputs to determine the
best settings on which to run the production equipment. Maintenance is
carried out at set intervals. This generally results in operational
inefficiency and unsafe operating conditions.
 Process automation simplifies this with the help of sensors at thousands of
spots around the plant that collect data on temperatures, pressures, flows
and so on. The information is stored and analyzed on a computer and the
entire plant and each piece of production equipment can be monitored on a
large screen in a control room.
LITERATURE REVIEW
15

16.  Plant operating settings are then automatically adjusted to achieve
the optimum production. Plant operators can manually override the
process automation systems when necessary.
Screenshot of SIEMENS SEMATIC MANAGER STEP 7 (S7) Software
LITERATURE REVIEW
FIGURE 5
16

17. Screenshot of SIEMENS LAD/STL/FBD (FB1) STEP 7 Software
LITERATURE REVIEW
FIGURE 6
17

18. SCREENSHOT OF SIEMENS LAD/STL/FBD (FB2) STEP 7 SOFTWARE
LITERATURE REVIEW
FIGURE 7
18

19. IMPORTANCE OF THE PROJECT
 With the development of this project, it will significantly reduces
the labor cost and improves the performance of plant in the
manufacturing industry.
 Operators can save time as well because information is gathered
by SCADA at a central location so that a personnel does not have
to go and wander about on site.
 It has the capability of displaying the trends. When information
gathered is displayed graphically, the system shows the developing
problems and help the operators in taking the corrective measures.
19

20. A Pictorial View of SCADA (ECS) SOFTWARE in Control System Lab
IMPORTANCE OF THE PROJECT
FIGURE 8
20

21. OBJECTIVES OF THE PROJECT
 The Automated System developed can be used in various
processes of Manufacturing Industry such as Cement Plant.
 The main focus of this project is controlling a unidirectional
motor for crusher section of a cement plant using Siemens
PLC controller Hardware .
 In Cement Industry, Crusher is used to crush the raw
materials such as limestone brought from quarry mines by
quarry trucks into tiny balls.
21

22. OBJECTIVES OF THE PROJECT
Limestone Crushing Process
FIGURE 9
22

23. METHODOLOGY
Assumptions Made during the design of Motor Block and Group
Control Block
23
The Motor which is controlled is assumed to be unidirectional motor
i.e. Motor runs only in forward direction.
It is assumed that only single motor can be controlled by a Motor
Block.
The Group Control Block can however control “n” number of
Motors, where “n” can be any number grater than one.
The Auto, Local Mode and Inputs and Outputs are assumed to
predefined.

24. 24
 Software and Hardware Tool Package used:
 PLC SIEMENS SIMATIC S7 Software
 Expert Control System (ECS) SCADA Software
 SIEMENS 400 Station PLC Hardware
METHODOLOGY

25. 25
Methodology and Experimental Setup for development of Motor
Block and Group Control Block
 The PLC logics were developed in Step 7 (S7) Siemens Software.
 Two different blocks were developed using Siemens Software
namely :
1. Motor Block
2. Group Control Block
METHODOLOGY

26. 26
PURPOSE OF MOTOR BLOCK AND GROUP CONTROL
BLOCK
 The Motor Block developed will help in controlling and running of
unidirectional motors.
 These unidirectional motors can be any numbers.
 The unidirectional motors can be used to supply power to crusher,
kiln, preheater, logistics, etc. of a cement plant.
METHODOLOGY

27. 27
 In development of Motor Block, following INPUTS were used:
MCC Signals
a) Motor Ready (RDY)
b) Run Feedback (RFB)
c) Local Stop (LSP)
d) Local Start (LST)
e) Overload (OVL)
Interlocks
a) Safety Interlock (SAF)
b) Sequential Interlock (SQI)
c) Process Interlock (PRO)
d) Start Interlock (STI)
METHODOLOGY

28. 28
 The OUTPUTS used in Motor Block were:
a) Motor Okay (MOK)
b) Command 1 (COM1)
c) Motor Run (MRN)
d) Trip (TRIP)
e) Motor Run Delay (MRD)
METHODOLOGY

29. 29
 MOTOR BLOCK :
METHODOLOGY
FIGURE 10
Motor Block Diagram

30. 30
FUNCTIONALITY OF MOTOR BLOCK:
 In Motor Block, the unidirectional motor runs in local mode and
can be made to run in auto mode through group control block.
 There is a local start and local stop inputs for operating the motor in
local mode.
 A series of interlocks allow the operation of the device.
 These interlocks are logically combined and declared in the IN
(Input) side when Function Block of the motor is processed.
METHODOLOGY

31. 31
FUNCTIONALITY OF MOTOR BLOCK:
 Run Feedback from the motor must appear within a certain time.
Otherwise it is assumed that an error or fault has occurred. This
function then stops the motor.
 The time and the duration of the fault/error is specified.
 If the start (local) button is pressed and motor enabled, the
unidirectional motor switches itself on, and runs until stop button is
pressed.
 When the device is switched on a timer starts to run. If the response
signal is not received before the timer has expired, the
unidirectional motor will stop.
METHODOLOGY

32. 32
 In development of Group Control Block following
INPUTS were used :
a) Group Ready (GRDY)
b) Group Start Interlock (GSTI)
c) Group Sequential Interlock (GSQI)
d) Start (STA)
e) Stop (STP)
f) Group Start Feedback (GSTFB)
g) Group Stop Feedback (GSTPFB)
METHODOLOGY

33. 33
 The OUTPUTS used in Group Control Block are :
a) Group Okay (GOK)
b) Group Run (GRUN)
c) Group Start (GST)
d) Trip
e) Group Stop (GSP)
f) Group Selection Bit (GSEL)
METHODOLOGY

34. 34
 GROUP CONTROL BLOCK
METHODOLOGY
FIGURE 11
Group Control Block Diagram

35. 35
FUNCTIONALITY OF GROUP CONTROL BLOCK:
 In Group Control Block, the unidirectional motor runs in both
local and auto mode.
 There are only two interlocks namely Start interlock and
Sequential interlock in contrary to four interlocks in Motor Block.
The Safety interlock and Process interlock are missing in Group
Control Block.
 As in Motor Block, the various interlocks allow the operation of
the unidirectional motor.
METHODOLOGY

36. 36
FUNCTIONALITY OF GROUP CONTROL BLOCK:
 Like in Motor Block, these interlocks are logically combined and
declared with the start (local and auto) and stop (local and auto)
inputs in the IN (Input) side when Function Block of the motor is
processed.
 In Group Control Block, the Run Feedback is divided into Group
Start Feedback and Group Stop Feedback. This Start and Stop
Feedbacks from the motor must appear within a certain time.
Otherwise it is assumed that an error or fault has occurred. This
function then stops the motor.
METHODOLOGY

37. 37
FEATURES OF MOTOR BLOCK AND GROUP CONTROL
BLOCK
The Motor Block and Group Control Block has number of features in
terms of interlocks present. There are four different types of interlocks.
They are :
Safety Interlock : The function of this interlock is to provide the safe
operation of the unidirectional motor for example proper temperature
and pressure conditions, etc..This interlock is applicable only to
individual unidirectional motor and hence absent in Group Control
Block.
 Sequential Interlock : Its function is to provide the sequential
operation of a number of motors. If any motor in the sequence fails, it
will give a return error.
METHODOLOGY

38. 38
FEATURES OF MOTOR BLOCK AND GROUP CONTROL
BLOCK
 Process Interlock : The function of this Interlock is to provide
smooth operation (motion detector) of the number of processes taking
place in the individual unidirectional motor. Since the processes are for
a single individual motor, this interlock is present only in Motor Block.
 Start Interlock : The function of this interlock is to provide the
proper starting of the unidirectional motor(s).
METHODOLOGY

39. 39
METHODOLOGY
Design of Faceplates for Motor Block and Group Control Block
After the development of Motor Block and Group Control Block in
SIEMENS S7 Software and downloading the block logics into the PLC
Hardware, faceplates are designed for motor blocks and group control
block.
To develop the Faceplates, it is necessary to create Submods. Submods
are the parts of faceplates.
 For a Motor Block and Group Control Block, total six Submods will be
created.

40. 40
 SUBMODS
The Submods consists of the following:
 INPUTS defined for the Motor Block and Group Control Block in
SIMATIC S7 Software.
 OUTPUTS defined for the Motor Block and Group Control Block
in SIMATIC S7 Software.
 The Modes i.e. the Local Mode and Auto Mode and Start and Stop
Buttons will also be present in a submod.
METHODOLOGY

41. 41
The Screenshots showing how a submod is designed is as shown below:
1. Motor Block Submods
METHODOLOGY
Figure 12
Screenshot showing Submod for Start and Stop (Auto and Local Mode)

42. 42
METHODOLOGY
Figure 13
Screenshot showing Submod for Inputs of Motor Blcok

43. 43
METHODOLOGY
Figure 14
Screenshot showing Submod for Outputs of Motor Block

44. 44
2. Group Control Block Submods
METHODOLOGY
Figure 15
Screenshot showing Submod for Start and Stop (Auto and Local Mode)

45. 45
METHODOLOGY
Figure 16
Screenshot showing Submod for Inputs of Group Control Block

46. 46
METHODOLOGY
Figure 17
Screenshot showing Submod for Outputs of Group Control Block

47. 47
 The following Screenshots shows how Faceplates are designed from the developed
Submods:
METHODOLOGY
Figure 18
Screenshot showing the Faceplate of a Motor Block (Combination of three
Submods of Motor Block)

48. 48
METHODOLOGY
Figure 19
Screenshot showing the Faceplate of a Group Control Block (Combination of
three Submods of Group Control Block)

49. 49
METHODOLOGY
FIGURE 20
A Typical Layout for Crusher in Cement Plant (Run-Time Mode)

50. 50
Testing of Motor Block and Group Control Block with PLC
Hardware and SCADA
 The PC in which the logics (Motor Block and Group Control Block)
are created is connected to the PLC Hardware through an Ethernet
Cable.
 The Program i.e. the logics are transferred through this Ethernet
module from the PLC Software to PLC Hardware.
 The SCADA and PLC Hardware are then made to communicate
with each other through Ethernet Communication Protocol.
METHODOLOGY

51. 51
Testing of Motor Block and Group Control Block with PLC
Hardware and SCADA
 The Crusher section created in the ECS software is then converted
from editor mode to run time mode.
 In this run time mode, the buttons present on the faceplates for the
crusher section can be operated and thus, the crusher (section) of a
cement plant can be automated.
METHODOLOGY

52. RESULT OBTAINED
52
Result Analysis (Graphical Representation)
FIGURE 21 Graphical Representation of Human Machine Interface (HMI)
showing the status of starting of Unidirectional Motor

53. 53
 SIGNIFICANCE OF RESULT
 The logics were used to develop a Motor Block and a Group
Control Block.
 The two Blocks developed and downloaded into PLC Hardware can
be integrated with SCADA and be used to control a unidirectional
Motor in Crusher of a cement plant.
RESULT OBTAINED

54. 54
 SIGNIFICANCE OF RESULT
 The Submods were made in ECS SCADA Software, which contains
Auto, Local Mode, and Inputs and Outputs defined in the SIEMENS
PLC Software as separate Submods.
 These six Submods (three each for Motor Block and Group Control
Block) are the integrated into two faceplates one each for Motor
Block and Group Control Block.
 The Inputs and Outputs will be visible as buttons in the faceplates and
can used to operate the manufacturing plant through SCADA from a
central location with RTU’s (Remote Telemetry Units), similar to PLC
mounted at different parts of a manufacturing plant.
RESULT OBTAINED

55. FINAL CONCLUSION
55
 With the development of this project, it will significantly reduce the
labor cost and improves the performance of plant in the
manufacturing industry.
 Management can save time as well because information is gathered
by SCADA at a central location so that personnel do not have to go
and wander about on site.
 It has the capability of displaying the trends. When information
gathered is displayed graphically, the system shows the developing
problems and helps the management in taking the corrective
measures.

56. 56
 It will be the one system that will keep running everything
perfectly, smoothly and fast.
 The Automated System developed can be used in various processes
of Manufacturing Industry such as Cement Plant.
 The main focus of this project is controlling a unidirectional motor
used in a Crusher section of a Cement Plant using Siemens PLC
controller Hardware.
 The unidirectional Motor thus can be used to control or run
different parts of a Cement Plant.
FINAL CONCLUSION

57. PRESENT SCOPE OF THE PROJECT
57
The Automated System developed can be used for the various other
purposes apart from Cement Industry. Following are some of the
areas where this automation system is employed:
1) Automated Manufacturing
2) Industrial automation
3) Process Automation in Mineral Industry
4) Agriculture Automation
5) Numerical Control (NC) Automation

58. REFERENCES
58
 Reference / Hand Books
[1] “SIEMPPERLENS STEP 7(S7) ACESYS-Reference Manual”,
PE+FUCHS Publisher (Germany), Edition 2008, Part No. 194576
08 /10 05
[2] “SENSORS FOR FACTORY AUTOMATION”,
PEPPERL+FUCHS Publisher (Germany), Edition 2008, Part No.
193679 04/08 01

59. 59
 Web
[1] PLC Basics and Communication Protocols, www.plcmanual.com
[2] Expert Control System (ECS) SCADA Software,
www.flsmidth.com/automation
[3] SIEMENS SIMATIC STEP7 (S7) Software,
www.automation.siemens.com
REFERENCES