Fluid Management System

Fluid Management SystemCAREER EPISODE 1INTRODUCTIONCE 1.1Project cognomen Fluid Management System was completed in my last year of Bachelor Degree program. I completed my Bachelors of engineer Technologist in Mechatronics from Chisholm Institute, Dandenong, Australia. My initial career episode is based on this brook experience that I gained and performed for the fulfillment of my trim placement. The picture was completed in 13 weeks, from July 2015 to October 2015. I was assisted and guided by Prof. Francis Percy, lecturer of Advance PLC.BACKGROUNDCE 1.2 Nature of projectMy project pee charge organization operated on six diametrical humors, operator can replenishment between different modes with the help of control panels that are mounted on individu altogethery operating mode switch. It has 2 modes for each operational mode i.e. Automatic and Manual mode. 1 is used to represent Automatic mode and 2 for Manual mode. There are in addition auto-manual switch selectors. The mode is chosen based on the way user wants to operate. For this purpose, SCADA PLC computer programming is done to provide user friendliness.CE 1.3The pump MDC 118 operates when the ice chest 1 or 2 is filled from the holding army tank whereas MDC 103 operates when modify it between tank 1to tank 2 or vice-versa. The six operational modes areOperation mode 1 fills tank 1 from holding tank done SV321 value (energized) and SV322(deenergized).Operational mode 2 fills tank 2 from holding tank through SV321 and SV322 valves (deenergized).Operational mode 3 fills tank 1 which has an analog sensor to manage the start and rub level for the filling with exact value from tank 2 through SV323 deenergized valve and SV324 energize value.Operational mode 4 fills tank 3 which has a digital and capacitive sensor to manage the start and stop level for the filling with capacitive sensors, LSL 532 and LSH 531 from tank 2 through SV323 energized valve and SV324 deenergize value.Operational m ode 5 fills the holding tank to tank 1 and at the same(p) time, transfers tank 1 to tank 2 through SV321 (energized), SV322 (de-energized), SV323 (de-energized) and SV324 (energized). It also maintains a set point for filling the tanks.Operation mode 6 fills the holding tank to tank 2 and at the same time, transfers tank 2 to tank 1 through SV321 (energized), SV322 (energized), SV323 (energized) and SV324 (de-energized). It also maintains a set point for filling the tanks.CE 1.4 ObjectivesTo prove my everyplaceall understanding on automation organisation, I had to complete a project. I chose a project that was based on how the automation system works in manufacturing industry of advance PLC department. And as per my project requirement I had to perform PLC and SCADA programming. Based on the two choices given to me, from Fluid counsel system and Pressure management system, I chose Fluid management system. The objective was to make a complete a fully automated fluid management s ystem using PLC programming with an HMI/SCADA in 13 weeks duration. It should consist of 3 water tanks, 2 pumps, number of 2 3 way valves using Allen Bradely software package IFIX SCADA software and various fluid level measuring instrument.It was further required toProgram PLC for six operating modesWhile implementing all the hardware like speck lights operating lightsSCADA programmingInterfacing.CE 1.5 The chart of organizational structureCE 1.5 Duties I studied and researched the basic architecture of the fluid management system which include PLC CPU (Allan Bradley), stratagem Net Scanner and plow I/O, RSlogix 5000(PLC programming software), HMI interact and software.I prepared the fluid management trainer system Device Net Network Set up.I created the PLC CPU DeviceNet scanner staff interfaceI create the mapping DeviceNet Nodes foreplay and outputs to the DeviceNet Scanner faculty stimulus and output registers.Performed commissioning and testing of a PLC systemCoded t he PLC programming for the water station for six different operating modes.Represent all the different modes to executive program, explaining them how it works. diving event and providing time slots to team members.Maintaining balance and peace to avoid conflict among each other.Kept good relations with supervisor.Reporting the development of the project to the testing ground supervisor and coordinator.PERSONAL ENGINEERING ACTIVITYCE 1.6 The project I have done related to the educational qualifications that I have obtained in my degree course. The kin between the different modules and project processes is explained at a lower placePLC (Program logic control) Here, I learned how to write PLC program with Allen Bradley software by using RS logic 5000. This skill was instrumental in completing my programming mark for water station.Instrumental Principal This module gave me the knowledge about sensors, how they work and wiring of the sensors, how you can program them. For this pr oject, I have used electronics level sensor LK31 and Impeller flow meter. Electronics level sensor determine the level of fluid according to the capacitive measuring principal.Industrial Networking My project involved the knowledge of DeviceNet and scanner which was learnt from this module.Project management Project management module skills were completely applied at all the stages of project. The project was also dual-lane in to two parts. All the tasks were scheduled and divided accordingly. I applied various techniques to practical implementation that learnt from project management.Mathematics and Fluid Mechanics My project involved a lot of calculation for example, the calculations to find torque, force, and power for the motor along with the calculations done to find the physical parameters of components. I also did the calculations to select the pulley-block and belt as well.Professional Engineering Technologist During the project life cycle, while working with Water station, I had to rely on the communication skills. The work experience gained during this project demonstrated how important the communication skills are to the professional engineering technologist.CE 1.7As a group project, I had to separate the system which contains two main part PLC programming and SCADA programming. I decided to complete the PLC programming and assigning my mate mater the SCADA programming. In PLC Program subroutine, to make the programming easy for controlling, for finding faults and for easy access to different part of programming, I had to split the main routine into different subroutine. This process can be seen infra introduce 1 PLC Program design ruleologyCE 1.8To prevent the occurrence of PLC program interlocking, this technique of energization of one contractor prevents the energization of other until it is in use. This method is called interlocking and I used interlock as a pre-requirement of the task to run the program. Various safety factor and other rea sons such as handle/Motor Faults, pressure requirement of system etc. are considered to run the function of PLC properly. It also makes the programming part easy, for this only writing the code logic of interlocking at one place is required and the same code is used as a pre-requirement of task at another place.Figure 2 logic of interlock in one place and use interlock as pre-requirement of taskCE 1.9Considering the program logic interlock as gist fault. It means, that if there is no pump fault, then the PLC will start running normally. Once the PLC starts running, it starts to operate in mode 1. In programming mode one, filling the tank 1 from holding tank through SV 321 valve (energized) and SV 322 valve (de-energized) is done. For the PLC program to be permissive, i.e. each process condition undertaken is called a permissive. For example, consider permissive to be a burner control for large combustion furnaces. To start the burners in a large furnace safely, the control system requests permission from several process switches, including high and low raise pressure, air fan flow check, exhaust stack damper position, access door position, etc. Every process condition that it undergoes is called a permissive. In the below diagram, it is control to fill the tank 1 by tank level permissive, if water level is below 10cm it will start filling tank until to reaches 13cm.Figure 3 PLC program permissiveCE 1.10Once the PLC program was completed and along with all the DeviceNet IOs pre-commissioned, registered and labelled in the PLC controller memory I started to design each operating modes. I started with operating mode 1. Once the programming of operation mode 1 and 2 was completed and it started working as intended, I could test the rest of the inputs in the system which were the water level sensors. While programming I constantly referred to operating mode table that I do using various engineering tools. Once the basic idea was plotted in the table format, the programming of remaining operating modes was successfully completed and also some extra additional features were added.Figure 4 Operating mode tableCE 1.11In the system architecture, there is a PLC CPU, DeviceNet Scanner and Flex I/O, RS logic 5000, PLC program and SCADA IFIX program. DeviceNet is a network system that is used in the automation industry to interconnect control devices for data exchange. In the water management system, there is a DeviceNet scanner node. In a typical configuration, the scanner module acts as an interface between DeviceNet devices and the programmable controller. The scanner module communicates with DeviceNet devices over the network toRead inputs from slave devicesWrite outputs to slave devicesCommunicate with peer devices.DeviceNet nodes setup as followsNode 0 1794-SDN Compact Logix DeviceNet Scanner/Master Module used for DeviceNet network control and data exchange with the PLC CPU.Node 1 Allen Bradley Flex IO distributed IO system.Node 2 Allen Bra dley DeviceNet interface Stack Light system.Node 4 Allen Bradley Variable Speed Drive used for speed control of pump MDC118CE 1.12I started performing test runs at the final stage, which includes analyze all the cable connections between the PLC and the plant are complete, safe, and to the required specification that meets the local standards.Checked that all the incoming power supply matches the voltage setting for which the PLC is set.Checked all protective devices are set to their appropriate trip settings.Checked that emergency stop button.Checked that all input/output devices are machine-accessible to the correct input/output points and giving the correct signals.And checked the FLEX I/O system that contains a network adapter, terminal bases, and I/O modules.CE 1.13After performing the above troubleshooting, the only problem I faced during the implementation of the whole system was that the Emergency stop button wasnt working. To solve this issue, I took various steps. I star ted by checking the connections. The first module is 1794-ADN DeviceNet Gateway module which is used to communicate and transfer data between the DeviceNet Master Module and the Flex IO modules 2 4. And the module the next 3 modules in order from 2 to 4 are 1794-IB32 Digital Input Module1794-IE4XOE2 Analog Input/output combination module1794-OB16 Digital Output Module.I checked the digital and analog input connection with emergency button with help of my lab supervisor and realized the problem was regarding the analog and digital input only, so I tried to resolve it by doing a research and taking suggestions from supervisors. analysisCE 1.14I successfully achieved all the objectives of the project within specified time limit and I gained good knowledge from this project as I did intense research about sensors and PLC programing for my project in the form of literature review. This had added many useful engineering techniques to my knowledge and enhanced my problem work out and analytical skills. In addition to that, I also implemented and used my engineering knowledge to make this project successful. I used concepts of various Engineering techniques and PLC programing which I had studied during my course of Bachelor of engineering technologist in Mechatronics. I presented a project thesis and seminar on my work on submission of my project.