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CHAPTER 1
INTRODUCTION

1.1 What is ash handling?

Ash handling refers to the method of collection, conveying, interim storage and load out of
various types of ash residue left over from solid fuel combustion processes.

The most common types of ash include bottom ash, bed ash, fly ash and ash clinkers resulting
from the combustion of coal, wood and other solid fuels.

Ash handling systems may employ pneumatic ash conveying or mechanical ash conveyors.

A typical pneumatic ash handling system will employ vacuum pneumatic ash collection and
ash conveying from several ash pick up stations-with delivery to an ash storage silo for
interim holding prior to load out and transport. Pressurized pneumatic ash conveying may
also be employed.

Coarse ash material such as bottom ash is most often crushed in clinker grinders (crushers)
prior to being transported in the ash conveyor system.

Very finely sized fly ash often accounts for the major portion of the material conveyed in an
ash handling system. It is collected from baghouse type dust collectors, electrostatic
precipitators and other apparatus in the flue gas processing stream.

Ash mixers (conditioners) and dry dustless telescopic devices are used to prepare ash for
transfer from the ash storage silo to transport vehicles.

1.2 Pneumatic ash handling system:

Pressurized pneumatic ash handling systems are most often
used for conveying ash over long distances. Such systems are also usefully applied when ash
is to be delivered to multiple interim storage or load out stations.

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An upstream mechanical blower creates a flow of conveying air. Ash is transferred from
collection hoppers to the conveying pipeline on a programmed cycle with the use of rotary
airlock feeders or double dump gate airlock valves.

At the end of the ash conveying pipeline ash is received in a highly abrasion resistant silo
mounted target box from which it falls by gravity into the storage silo.

Ash conveying air is normally exhausted to the atmosphere through a silo vent filter or it can
be recycled to other dust collection equipment.

FIG 1 : Pneumatic Ash Handling Unit.

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Chapter 2
About the Project

During our industrial case study in III year we went to mecghale pneumatics india pvt. Ltd.
To know about their product that is Ash handling systems, on studying more about the
systems we came to know about the constant seal failure of the dome valve which was the
heart of the system. So we decided to take this system as our major project. It was observed
that conveying pressure was not constant, and if conveying pressure was greater than Seal
pressure the ash is not conveyed to Silo and damages the pneumatic Seal. Upon taking a
closer look on the pilot plan of the system we came up with a suggestion of installing a PLC
circuit to keep pressure in the system constant, which in turn will increase the life of the seal.

2.1 Objectives:
 To study about ash handling plant.
 To Suggesting feasible solution.
 Valve sizing.
 To Study about how pressure controlling valve controlled by PLC.

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Chapter 3
About Industry
3.1 Profile:

Established in the year 1994, at Nagpur, Maharashtra, India, they “Mecgale Pneumatics
Private Limited,” are a leading Engineering company offering expertise in the field of
manufacturing and supplying of Pneumatic Conveying Systems, Ash Handling Systems, Raw
water intake equipments, Process equipments, Technological structures, Powercon Dense
Phase Conveying System, Controlcon Dense Phase Conveying System, Unicon Dense Phase
Conveying System, Traveling Water Screen, Stop Log Gate, Steel Trash Rack, High
Concentration Slurry Disposal System (HCSD), Belt Conveyor, Bucket Elevator, Screw
Conveyor, Clariflocculator, Material Feeding Arrangements. Other than this, our well-
equipped modern manufacturing, in-house design facility and service support of experienced
industry professionals also allow us to successfully execute turnkey projects in this field.

A big supporter of merit shop concept, today, they have gained expertise in providing there
customers with scheduling flexibility & management control of resources, thus assuring on-
time completion of projects handled by us within defined budget restrictions. Further, our on-
going investment in the field of research & innovation also leads to coming up with new
technologies, thus allowing us to offer customers most advanced production techniques
available. This leads to maximized cost-effectiveness and efficiency from our end.

3.2 Company Fact File:

3.2.1 Basic information:

Type of industry Original Equipment Manufacturer
Additional Business  Manufacturer
 Supplier
 Service Provider

Year of establishment 1994

Ownership Private Limited Company
Annual Turnover Rs. 100 - 500 Crore

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Chapter 4
Introduction to Ash Handling system of Mecgale Pneumatics
4.1 General Principle of operation:
Dry Fly Ash collected in Boiler bank hopper, ECO & APH hopper, and ESP field hopper

Is pneumatically transported to the Fly Ash Storage Silo of capacity through 65NB conveying
pipe and Terminal End Box.

Conveying air of the Storage Silo is cleaned through a Reverse Pulse Jet type Bag Filter and
is then discharged into the atmosphere.

Further Disposal of the Ash from Fly Ash Silo is done in wet form through Ash

Conditioner and in Dry form though telescopic Chute up to the trolley or truck.

All the conveying systems have dual operability either through level probe or through

Auto timer. In timer mode of operation, the system goes on continuous cycles after a

present time interval even if there is a little or no material to convey.

The Inlet Valve on the top of the vessel opens quickly as there is a Quick Exhaust Valve

Fitted to the inlet of the seal and to the Cylinder and allows material to gravitate into

The vessel. The valve closes after the preset adjustable time delay or by level probe fitted

in the vessel.

Once the valve closing is ensured through an air limit switch valve its circumferential

Inflatable seal inflates slowly as there is a bleed nipple over limit switch which prevents

the Dome wearing on Seal failure and ensures complete leak-proof.

Conveying air is injected into the vessel after ensuring seal pressure is O.K. sensed

through a Pressure switch mounted in the Pneumatic Panel. Thus vessel is pressurised

and material resistance leads to pressure build-up which conveys the material to the

destination point.

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When conveying is complete, the vessel pressure drops down to near atmospheric

pressure and is sensed by another pressure switch mounted in the pneumatic panel. The

conveying air supply to the system is then stopped.

Now the system is ready to accept next charge of material on command from level

probe/auto timer after a time gap. This time gap is Cycle Reset Time.

Normally the destination side is also provided with a high level switch, which gives an

alarm when filled up and prevents any further transfer of material into it. If the alarm

comes in between the running cycle the system will complete the cycle and stop the

system from further cycle. Next cycle will start after the silo high level alarm turns off.

4.2 Conveying System operating cycle:

The Pneumatic circuit is shown in the enclosed diagram and the basic principle of

Operation is as follows:

 The main conveying air passes through an isolating ball valve and a pneumatically
operated two way full flow type valve and then enters the conveying chamber via the
flow control orifice plate(s).
 The orifice plate(s) control the amount of air consumed during conveying and also
provides the necessary restriction to allow the pressure in the conveying vessel to
drop to near atmospheric pressure when conveying is completed.
 The Pneumatic Circuit functions in the following sequence:
 The Inlet Valve is normally closed and the electrical system operates a
Solenoid Valve which opens the Inlet Valve. The seal air and pneumatic
cylinder air escapes through a Quick Exhaust Valve mounted on the inlet of
seal air and rear end of the cylinder ensuring quick opening of the valve.

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 A timer keeps the Inlet Valve open for a set time to allow the conveying
chamber to fill.
 After elapse of set time the solenoid valve de-actuates which in turn closes
the Inlet valve and provides air to the Limit Switch Valve. The Limit Switch
valve operates on ensuring closure of Inlet Valve and provides air to the
Inflatable seal of the Inlet Valve through a bleed nipple which ensures slow
inflation of the seal and thus reducing wear & tear of the seal & dome. Once
the seal pressure is ensured through a pressure switch, the main conveying
air valve opens allowing air into the conveying chamber.
 After completion of material conveying, the resultant pressure drop in the
conveying system drop which is sensed by a pressure switch.
 The above low conveying vessel pressure signal in turn activates the main
conveying air valve to close.
 The Inlet Valve then remains closed with its seal inflated until a further batch
of material is required to be conveyed.
 This system does not allow material to be present in the conveying system
larger than the time required to fill the conveying vessel and to convey it.

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Fig2: Pneumatic conveying system.

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Chapter 5
Components used in Pneumatic Conveying System:

5.1 Dome Valve:

Fig 3: Pneumatic operated dome valve.

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5.1.1 Principle of operation:

The Dome component closes beneath the seat (seal) when the seal is relaxed (not
inflated), allowing a controlled gap between the seat (seal) and the closing member
(Dome). Material is allowed to pass through or enter the controlled gap if, due to its
characteristics, it is pulled into the gap by the action of the Dome component moving
to its closed position.

In the closed position, high pressure air or other gas enters the space between the back
of the seal face and the insert ring to cause the seal face to expand onto and around the
periphery of the Dome component. Material particles are entrapped by the seal against
the dome surface, irrespective of particle size or shape. Before opening the valve, the
seat is relaxed, and the controlled gap is re-established before the Dome component
moves to its open position. The seal is a loose component clamped into place by a
spigot piece and external fasteners holding the top plate assembly
to the body. The seal is easily removed for inspection.

5.1.2 Inflatable Seats:

Inflatable flexible seats entrap particles that are normally the cause of seat erosion.
Particles are induced to move across valve seats under the influence of pressure
differentials on either side of the closing member. Entrapping particles within a
flexible face during the period of valve closure prevents particle movement and
considerably reduces valve seat wear. Inflatable seats allow automatic wear
compensation.

5.1.3 Types of Inflatable Seats type:

Flexible Seats

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Flexible seats that do not inflate require the force of engagement on closing to entrap
particles. However the flexible valve seat has limited life because the worn Surface of
the flexible seat cannot continue to reengage the closing member and entrap particles.
Inflatable seats compensate for wear to the seat and provide longer sealing life.

Hard Seats
The conventional hard material approach to valve seat life relies on crushing particles
between the faces. This approach does not attempt to entrap particles, but causes the
particles remaining to become very small to reduce their erosion effect on the valve
seat. However small the particles are, each particle contributes to continuing erosion.
Particle movement and initial erosion allows accelerated subsequent erosion since the
hard seats cannot compensate for wear.

Fig 4: Working of Pneumatic seal

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5.2 Pressure Switch:

A pressure switch for sensing fluid pressure contains a capsule, bellows, Bourdon
tube, diaphragm or piston element that deforms or displaces proportionally to the
applied pressure. The resulting motion is applied, either directly or through
amplifying levers, to a set of switch contacts. Since pressure may be changing slowly
and contacts should operate quickly, some kind of over-center mechanism such as a
miniature snap-action switch is used to ensure quick operation of the contacts. One
sensitive type of pressure switch uses mercury switches mounted on a Bourdon tube;
the shifting weight of the mercury provides a useful over-center characteristic.

The pressure switch may be adjustable, by moving the contacts or adjusting tension in
a counterbalance spring. Industrial pressure switches may have a calibrated scale and
pointer to show the set point of the switch. A pressure switch will have a differential
range around its set point in which small changes of pressure do not change the state
of the contacts. Some types allow adjustment of the differential.[1]

The pressure-sensing element of a pressure switch may be arranged to respond to the

difference of two pressures. Such switches are useful when the difference is
significant, for example, to detect a clogged filter in a water supply system. The
switches must be designed to respond only to the difference and not to false-operate
for changes in the common mode pressure.

The contacts of the pressure switch may be rated a few tenths of an ampere to around
15 amperes, with smaller ratings found on more sensitive switches. Often a pressure
switch will operate a relay or other control device, but some types can directly control
small electric motors or other loads.

Since the internal parts of the switch are exposed to the process fluid, they must be
chosen to balance strength and life expectancy against compatibility with process

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fluids. For example, rubber diaphragms are commonly used in contact with water, but
would quickly degrade if used in a system containing mineral oil.

Switches designed for use in hazardous areas with flammable gas have enclosure to
prevent an arc at the contacts from igniting the surrounding gas. Switch enclosures
may also be required to be weatherproof, corrosion resistant, or submersible.

An electronic pressure switch incorporates some variety of pressure transducer (strain

gauge, capacitive element, or other) and an internal circuit to compare the measured
pressure to a set point. Such devices may provide improved repeatability, accuracy
and precision over a mechanical switch.

Fig 5: Pressure switch

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5.3 No return valve:

A check valve, clack valve, non-return valve or one-way valve is a valve that
normally allows fluid (liquid or gas) to flow through it in only one direction.

Check valves are two-port valves, meaning they have two openings in the body, one
for fluid to enter and the other for fluid to leave. There are various types of check
valves used in a wide variety of applications. Check valves are often part of common
household items. Although they are available in a wide range of sizes and costs, check
valves generally are very small, simple, or inexpensive. Check valves work
automatically and most are not controlled by a person or any external control;

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accordingly, most do not have any valve handle or stem. The bodies (external shells)
of most check valves are made of plastic or metal.

An important concept in check valves is the cracking pressure which is the minimum
upstream pressure at which the valve will operate. Typically the check valve is
designed for and can therefore be specified for a specific cracking pressure.

Fig5: Valve closed

5.4 Quick Exhaust Valve:

The speed at which an air cylinder strokes is determined by how fast compressed air enters it
and how fast the air already in the cylinder exhausts to atmosphere. System pressure drives
air into the cylinder and this does not pose a speed problem in most circuits. Air leaving the
cylinder is different because it was at system pressure when the directional valve shifted.
Although the air starts exiting quickly, it still holds the piston back. Speeding up a sluggish
air-operated cylinder is best accomplished by dealing with its exhaust air. The cross-sectional
view and symbol in Figure 6 illustrate a quick exhaust valve, which does just that.

As the cylinder retracts and is held at rest, the shut-off wafer covers the exhaust port and
forces air to the cylinder rod end. When the directional valve shifts to extend the cylinder,

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pressure drops on the left side of the shut-off wafer and trapped pressure in the cylinder
forces the wafer to the left. As the shut-off wafer moves left, it closes off flow to the valve
and opens a direct path to atmosphere only a short distance from the cylinder port. The rapid
exhaust of air reduces backpressure on the cylinder piston, allowing high-pressure inlet air to
accelerate and move the piston very quickly.

Fig6: Quick Exhaust Valve

5.5 Exhaust Silencer:

The air-exhaust mufflers in Figure 7 reduce the noise level of air-operated equipment.
They are made in several different configurations out of many types of material, but
the end result of all of them is the smooth discharge of air.

The sintered-bronze elements on the left are similar to filters made of the same
material. They separate the flowing air into numerous paths to lessen or eliminate the
loud crash of air as it leaves an actuator. The sintered-bronze element in the center has
a protective metal covering and an adjustable poppet valve to control flow. It works as
an inexpensive meter-out flow control when used with a 5-way directional control
valve. Because a 5-way valve has two exhaust ports, these speed-control mufflers can

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regulate speed independently in both directions of travel. The muffler on the right is
similar to those used on internal combustion engines. It may be made of plastic or
aluminum. It is bulky, but causes less restriction on fast-moving actuators.

Fig 7: Exhaust Silencer

5.6 3/2 Single Solenoid valve:

The cross sectional view of 3/2 way single solenoid valve in the normal and actuated
positions are shown in Figure 8. In the normal position, port 1 is blocked and port 2 is
connected to port 3 via back slot (details shown in the circle) When the rated voltage
is applied to coil, armature is pulled towards the centre of the coil and in the process
the armatures is lifted away from the valve seat. The compressed air now flows from
port 1 to port 2, and ports 3 is blocked. When the voltage to the coil is removed, the
valve returns to the normal position. Figure 1.5 shows 2/2 solenoid operated valve

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Fig 8: 3/2 Single Solenoid valve.

5.7 5/2 Single Solenoid valve:

The cross section view of 5/2 way single solenoid in the normal and actuated
positions are shown in Figure 9. In normal position, port 1 is connected to port 2, port
4 is connected to port 5, and port 3 is blocked. When the rated voltage is applied to
coil 14, the valve is actuated through an internal pilot valve. In actuated position, port
1 is connected to port 4, port 2 is connected to port 3, and port 5 is blocked. The valve
returns to the normal position when the voltage to the armature coil is removed.
This type of valves is normally used as final valve to control double acting cylinders.

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Fig 9: 5/2 Single Solenoid valve.

5.8 Ash Vessel:

The Ash vessel is used where material from number of hoppers is collected in
different ash vessels and is conveyed through a single pipeline. All the ash vessels are
connected in series have independent dome valve, but the conveying air is controlled
by first vessel i.e. called Master Vessel. The other vessels are called Slave Vessels.

The Ash Vessel System operates on the principle of a high pressure, dense material
air mixture at a low velocity moving through the conveying pipe in separate batches
or plugs. The Ash Vessel comprises one piece body with a top inlet aperture and

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horizontal inlet and outlet aperture for conveying material. Mounted on the top inlet is
a Dome Valve. It has a controlled air supply for conveying the material.

Fig10: Ash Vessel.

Chapter 6
Problem &Its Solution
The Inlet Valve is normally closed and the electrical system operates a Solenoid
Valve which opens the Inlet Valve. The seal air and pneumatic cylinder air escapes
through a Quick Exhaust Valve mounted on the inlet of seal air and rear end of the
cylinder ensuring quick opening of the valve. A timer keeps the Inlet Valve open for a
set time to allow the conveying chamber to fill. After elapse of set time the solenoid
valve de-actuates which in turn closes the Inlet valve and provides air to the Limit
Switch Valve.

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The Limit Switch valve operates on ensuring closure of Inlet Valve and provides air
to the Inflatable seal of the Inlet Valve through a bleed nipple which ensures slow
inflation of the seal and thus reducing wear & tear of the seal & dome. Once the seal
pressure is ensured through a pressure switch, the main conveying air valve opens
allowing air into the conveying chamber. After completion of material conveying, the
resultant pressure drop in the conveying system drops down which is sensed by a
pressure switch.

Seal pressure should be always greater than conveying pressure. There was a
fluctuation to conveying pressure. If conveying pressure goes above seal pressure can
cause damage to pneumatic seal. This results in replacement of seal every month. This
increases cost and downtime of system.

In order to avoid fluctuation, Pressure Control Valve is provided to keep the pressure
constant. It is achieved by PID controller which is part of PLC. It gives signal to the
control valve in order to keep the pressure constant. Controller input is connected to
Pressure transmitter.

Controller output is connected to Current to pneumatic converter. Thus the output of

Current Pneumatic controller is connect to Pressure control valve and achieving a
constant pressure.

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Fig11: System after modification.

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6.2 Components used:

6.2.1Air Operated Diaphragm Control Valve:
Double seated, pneumatically controlled, regulating valves exhibit good balancing characteristics
essential for low-sensitivity applications because high pressure enters between the seats and creates
equal, but opposing forces.

Air operated diaphragm control valve and the control pilot valves used in controlling them (see
below) are available in many different configurations.

The air operated diaphragm control valve shown is direct acting. On direct acting valves the air from
a control source is applied to the top of the diaphragm. Reverse acting valves, the air is applied to
the under side of the diaphragm.

This valve is downward seating, air pressure applied to the top of the diaphragm with sufficient
pressure it over come the opposed spring tension will move the stem downward. This tends to close
the valve. The force exerted on the spring is equal to the air pressure multiplied by the area of the
diaphragm.

The valve stem is sealed with a packing gland, care must be taken when adjusting, binding will cause
erratic operation. Screwing down on sleeve adjusting nut lessens the spring tension causing the
valve, to close at a lower loading pressure. The spring force must be within the operating range of
the pilot output loading pressure.

Fig12: Air Operated Diaphragm Control Valve.

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6.2.2 Current and pressure transducer:

A “current to pressure transducer” converts an analogue signal to a proportional linear pneumatic
output. Its purpose is to translate the analog output from a control system into a precise,
repeatable pressure value to control pneumatic actuator, pneumatic valve, damper etc.

The I/P converter provides a reliable .repeatable, accurate means of converting an electrical signal
into pneumatic pressure in many control systems. Model of this device are usually available in direct
and reverse action and are field selectable with full or split range inputs as the may be.

The most common application of I/P transducer is to receive an electrical signal from a controller
and produce a proportional pneumatic output for operating a control valve or positioner. The device
can be mounted on the wall or a pipe stand or directly on the valve actuator. Where the device can
withstand vibrations, they are directly mounted on the actuator .In many instance, the device is
remotely mounted on instrument pipe stands to reduce vibration.

Operating Principle:

The I/P converter uses an electromagnetic force balance principle to change electrical signal int
pneumatic signals. Typically, 4-20mA input is converted int a 3-15pisg output. The operating
principle of the I/P transducer is shown in fig12. As shown in fig12, a coil produces the magnetic
field. Within the coil is a deflector motor with a flapper valve attached that operates against a
precision nozzle to create a back pressure on the servo diaphragm of a booster relay. The input
current flows in the coil and produces a force between the coil and the flapper valve, which controls
the servo pressure and the output pressure.

Fig12: Current and pressure Fig13: I/P Converter.

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Chapter 7
Programmable Logic controller (PLC)
7.1 Introduction:
A programmable logic controller, PLC, or programmable controller is a digital computer used for
automation of typically industrial electromechanical processes, such as control of machinery on
factory assembly lines, amusement rides, or light fixtures. PLCs are used in many machines, in many
industries. PLCs are designed for multiple arrangements of digital and analog inputs and outputs,
extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.
Programs to control machine operation are typically stored in battery-backed-up or non-volatile
memory. A PLC is an example of a "hard" real-time system since output results must be produced in
response to input conditions within a limited time, otherwise unintended operation will result.

Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles was
mainly composed of relays, cam timers, drum sequencers, and dedicated closed-loop controllers.
Since these could number in the hundreds or even thousands, the process for updating such facilities
for the yearly model change-over was very time consuming and expensive, as electricians needed to
individually rewire the relays to change their operational characteristics.

Digital computers, being general-purpose programmable devices, were soon applied to control of
industrial processes. Early computers required specialist programmers, and stringent operating
environmental control for temperature, cleanliness, and power quality. Using a general-purpose
computer for process control required protecting the computer from the plant floor conditions. An
industrial control computer would have several attributes: it would tolerate the shop-floor
environment, it would support discrete (bit-form) input and output in an easily extensible manner, it
would not require years of training to use, and it would permit its operation to be monitored. The
response time of any computer system must be fast enough to be useful for control; the required
speed varying according to the nature of the process.[1] Since many industrial processes have
timescales easily addressed by millisecond response times, modern (fast, small, reliable) electronics
greatly facilitate building reliable controllers, especially because performance can be traded off for
reliability.

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In 1968 GM Hydra-Matic (the automatic transmission division of General Motors) issued a request
for proposals for an electronic replacement for hard-wired relay systems based on a white paper
written by engineer Edward R. Clark. The winning proposal came from Bedford Associates of
Bedford, Massachusetts. The first PLC, designated the 084 because it was Bedford Associates' eighty-
fourth project, was the result.[2] Bedford Associates started a new company dedicated to
developing, manufacturing, selling, and servicing this new product: Modicon, which stood for
MOdular DIgital CONtroller. One of the people who worked on that project was Dick Morley, who is
considered to be the "father" of the PLC.[3] The Modicon brand was sold in 1977 to Gould
Electronics, later acquired by German Company AEG, and then by French Schneider Electric, the
current owner.

7.2 About the Software RS Logix 500:

INSTRUCTION – RSLogix’s command language is comprised of “instructions”. An XIC (it looks like a
normally open contact –] [– ) is an instruction. A timer is an instruction. A few of the most common
instructions are described below.

BIT – an address within the PLC. It can be an input, output or internal coil, among others.

In RSLogix, there are a couple of ways to show the address of a bit. The default is:

[type]:[word]/[bit]

For example, an address that references an output of an SLC 500 is O:5/0. That is:

O:5/0 means that it is a physical output.

O:5/0 means that it uses Slot 5 (the 6th physical slot) in the rack.

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O:5/0 means that it is the first output on the card.

Remember that the first slot in an SLC 500 rack is Slot 0. That means a card that is installed in the 6th
physical slot is addressed as Slot 5.

Allen-Bradley PLC slots, like many computers, always start with 0.

By the way, don’t get the capital “O’s” confused with zeroes.

RUNG – A section of the PLC ladder program that terminates in an output function of some type. Just
like in an electrical ladder diagram, a rung has some type of output that is turned on or turned off by
the preceding entities in the rung. The first rung in a ladder program is always 0000.

HARDWIRED INPUT – a physical connection to the PLC from an input device (switch or sensor, etc.).

Allen-Bradley uses the capital letter “I” to designate a hardwired input. An address that describes an
input on an SLC 500 is I:4/0.

Similar to the output structure,

I:4/0 means that it is a physical input.

I:4/0 means that it uses Slot 4 (the 5th slot in the rack).

I:4/0 means that it is the first input on the card.

Don’t get the capital “I’s” confused with ones.

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HARDWIRED OUTPUT – a physical connection from the PLC to an output device (relay or pilot light,
etc.) As was said above, an address that references an output of an SLC 500 is O:5/0.

INTERNAL COIL

This is a programmable bit used to simulate a relay within the PLC. The internal coil has no
connection to the outside world. It does not connect to an output card. Internal coils are used to
store information. The “contacts” of this “relay” can then be used multiple times in other parts of
the program.

In RSLogix, the “B3” (binary) file is commonly used for all the internal coils. There are many other
words in other files that have bits you can use as internal coils, but we are going to stick with the B3
file for our application.

B3:0/0 means that it references an internal Binary file

B3:0/0 means that it uses the first word in the table

B3:0/0 means that it is the first bit in the word.

Note that, unlike the Output and Input files, you have to use the file number in the address. In this
case, the default file number is 3.

TIMER

A timer is a programmable instruction that lets you turn on or turn off bits after a preset time.

The two primary types of timers are TON for “timer on delay” and TOF for “timer off delay”.

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Timers in A-B SLC and MicroLogix processors use file 4 for their timers.

T4:0 means that it references an internal Timer file

T4:0 means that it uses the first timer in the table

The address T4:0 simply refers to the timer. Each timer has bits that turn on after the timing function
is complete. You can address this bit by simply putting a “/DN” after the timer address. DN stands for
“done”.

For example, if timer T4:0 is a TON (timer on delay), then the bit T4:0/DN will turn on after the timer
has reached its preset value.

COUNTER

A counter is a programmable instruction that lets you turn on or turn off bits after a preset count has
been reached.

There are different types of counters available in the RSLogix, but the CTU (counter up) instruction
covers everything we will talk about here.

Counters in A-B SLC and MicroLogix processors use file 5.

C5:0 means that it references an internal Counter file

C5:0 means that it uses the first counter in the table

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The address C5:0 simply refers to the counter. Each counter has bits that turn on after the counting
function is complete. You can address this bit by simply putting a “/DN” after the counter address.
DN stands for “done”.

For example, if counter C5:0 is a CTU (counter up), then the bit C5:0/DN will turn on after the
counter has reached its preset value.

–] [– Normally Open Contact

When used with a hardwired input, this instruction is off until there is a voltage applied to the input.
The bit address then goes high, or on, and the instruction becomes “true.” It works the same way
when it has the same address as an internal coil, except that the coil must be turned on by logic in
the program.

Allen-Bradley calls these normally open contacts “XIC”, or “eXamine If Closed” instruction.

An XIC instruction can reference a hardwired input, a hardwired output, an internal coil or a timer
done bit, among others.

–]/[– Normally Closed Contact

This is an inverted normally open contact.

When used with a hardwired input, this instruction is “true” until there is a voltage applied to the
input. It then goes low, or off, and becomes “false.”

It also can be used with an internal coil, becoming true when the coil is off and becoming false when
the coil is on.

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Allen-Bradley calls these normally closed contacts “XIO”, or “eXamine If Open” instructions.

-( )- Output Coil

When used with a hardwired output, this function is off until the logic in the program allows it to
turn on. It then becomes “true”, and will energize the device that is wired to the respective output.

If it is used as an internal coil, it will toggle the instructions associated with it. That is, it will close a
normally open instruction and open a normally closed instruction.

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7.3 Ladder programming of Pneumatic Conveying system:

Fig14: Ladder programming in Rs Logix 500.

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Input/output sheet:

Fig15: Input/output sheet.

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8.CONCLUSION

8.1 PROJECT OUTCOME

Before installing the PLC for the system the seal had to replaced every 15 days. And the cost
of a seal is Rs. 10,000 and a system consists of minimum four seals and the cost of seals per
year will mount upto Rs. 80000 per month and the loss occurred during the downtime of the
machine. Upon installing the PLC the life of the seal increased to about 3-4 months, which
would cost upto Rs. 10000 per month. The cost of the PLC is Rs. 100000. Thus the annual
savings done by installing the PLC is upto Rs. 7 lakh plus the reduced downtime of the
machineries.

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Mechanical Engg Department: St Vincent Pallotti college of Engg & Tech