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Assignment PLC Document

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8 views

Assignment PLC Document

Uploaded by

hau.pham210
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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I.

System abstract
Task: Control of a system that mixes two types of ingredients A and B, then pours them into a finished
product tank.
Design philosophy:
System preconditions and readiness checks

- The reactor tank must be empty and at the specified temperature (100°C) before starting
the addition of any ingredients. This is to ensure that:
- No residual material from previous batches remains, which could affect the chemical
properties of the new mixture.
- The correct mixing temperature is achieved to prevent any issues with ingredient
solubility or chemical reactions.
- The system will rely on the normally closed level switch (LLS) to confirm the empty
state, and the temperature sensor will verify that the tank is at 100°C. If either condition
is not met, the process will not start.
Mixer motor control

- The mixer motor remains off initially to avoid any early-stage precipitation of the
ingredients. The motor will only activate after both ingredients have been added, ensuring
homogenous mixing under controlled conditions.
- This reduces risks associated with partial reactions or unwanted precipitation due to
premature agitation.
Finished product tank position verification

- The system requires the finished product tank to be in the correct position before the
mixing process begins. This is monitored by a limit switch, ensuring that once the mixing
is completed, the mixture can immediately be transferred without delays.
Ingredient addition control and monitoring

Ingredient A:
- The controller opens solenoid valve 1 (SOL1) to allow ingredient A to flow into the
reactor.
- The level sensor LLS1 verifies when exactly 100 gallons of ingredient A have been added
by closing when the correct volume is reached.
Ingredient B:
- After ingredient A’s addition is verified, the controller opens solenoid valve 2 (SOL2) for
ingredient B.
- The level sensor LLS2 monitors and closes upon detecting that 400 gallons of ingredient
B have been added.
Temperature maintenance and control

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- During the ingredient addition, it is crucial to maintain the tank temperature within a 10%
tolerance of the initial 100°C (90°C to 110°C). The PLC will continuously monitor the
tank’s temperature and, if necessary, turn the heater ON to maintain the required
temperature range.
- This control mechanism ensures consistent chemical properties and reactions during the
mixing process, avoiding temperature-induced inconsistencies in the product quality.
Safety and error handling

- The PLC program should include safety interlocks to prevent overlapping actions or
undesirable events (e.g., if the temperature drops below the threshold or if any level
sensors indicate an incorrect reading).
- The system can trigger alarms if any condition deviates significantly from the set
requirements, alerting operators to potential issues like valve malfunctions, incorrect
ingredient levels, or temperature control failures.
Automation and system feedback

- Each step in the process is automated and controlled by the PLC, which manages
solenoid valves, heater activation, and sensor feedback to ensure a controlled, efficient
process.
- The system continuously monitors each parameter and provides feedback for real-time
adjustments, minimizing operator intervention and enhancing process reliability.
Flowchart
Objectives:

- Ensure consistent product quality by adding precise quantities of ingredients A (100


gallons) and B (400 gallons).
- Maintain reactor tank temperature within 100°C ± 10% to support proper mixing and
prevent precipitation.
- Verify reactor tank is empty and preheated before starting ingredient addition to avoid
contamination.
- Sequence the process to prevent premature mixing, spillage, and ensure safety.
- Utilize PLC automation for real-time monitoring, temperature adjustments, and efficient
control.
- Employ sensors and interlocks to monitor tank levels, temperature, and component
positions, providing immediate feedback.
- Minimize waste and downtime through automated, reliable control.
- Design for scalability and include troubleshooting features for easy maintenance and
future expansion.

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Fig 1. Mixing system and the flowchart for the mixing system

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Fig 2. Logic diagrams for the mixing system

II. System configuration


Student must design the system configuration for the system

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III. I/O wiring connection diagram

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IV. I/O address assignment

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V. Internal storage address assignment

VI. Control program

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