International Journal of Emerging Trends & Technology in Computer Science (IJETTCS)

Web Site: www.ijettcs.org Email: [email protected], [email protected]

Volume 2, Issue 5, September – October 2013 ISSN 2278-6856

Color making and mixing process using PLC

S.T.Sanamdikar andVartak C
Instrumentation &Control Dept.PDEA’s, COEM, Pune. India

Abstract––This paper outlines the various stages of operation processes it and presents it in values which can be
involved in the conversion of a manually operated color plants verified and compared with the standard values.
towards a fully automated color making plant. Over the years In the coding process of this implementation with micro-
the demand for high quality, greater efficiency and quantity has controller, it requires a fast and efficient processing
increased in this globalized world for various colors. The initial
which on the other part depends on the length and sub-
phase of the paper focuses on passing the inputs of color mixing
and making process with various components. With the help of
routines of the coding process. Thus it provides a real
mixing tanks all colors coming from the process will be mixed challenge with systems involving
in our required proportion .color will be mixed using mixed
motor .making color in industry which will used for food 3. METHODS
beverage industry.generally from three colors we are making To making the different colors in the industry we are
nine colors with different proportions so it will be used in using different methods they are given following-
different petrochemical companies.
1- User can select one of the six colors which are shown
on the HMI.
Index Terms––Automation, PLC , SCADA, color 2- User can create his own color with his own ratio of the
making and mixing three main colors.
3- User can be operated that plant by using machine and
1. INTRODUCTION human efforts or both.
Over the years the demand for high quality, greater
efficiency and automated machines has increased in the 4. CRITICAL CONTROL ARAMETERS
industrial sector of different plants. Many plants require INCOLOR MAKING PROCESS
continuous monitoring and inspection at frequent A. Level Control
intervals. There are possibilities of errors at measuring To control the level of mixing tank with the help of
and various stages involved with human workers and also ultrasonic transducer.
the lack of few features of microcontrollers. Thus this B. Speed Control
paper takes a sincere attempt to explain the advantages
To control the speed of the conveyor belt.
the companies will face by implementing automation into
them.
The process control of color making which is the most 5. AUTOMATION
important process in any color plant like Asian paints and Delegation of Human Control to technical Equipment
its automation is the precise effort of this paper. aimed towards achieving.
In order to automate a color plant and minimize human Advantages
intervention, there is a need to develop a SCADA Higher productivity, Superior quality of end product,
(Supervisory Control and DataAcquisition) system that efficient usage of raw materials and energy, improved
monitors the plant and helps reduce the errors caused by safety in working condition.
humans. While the SCADA is used to monitor the History of Control and Automation
system, PLC (Programmable Logic Controller)is also 1.PLC
used for the internal storage of instruction for the 2.Electrical Control with Logic gates
implementing function such as logic, sequencing, timing, 3.without Logic Gates
counting and arithmetic to control through digital or 4.Mannual Control
analog input/ output modules various types of machines
processes. Systems are used to monitor and control a Manual Control
plant or equipment in industries such as In this, the Control and Automation are done by Manual
telecommunications, water and waste control, energy, oil Operations.
and gas refining and transportation. Drawbacks:
•Human Errors subsequently affect quality of end product.
2. DRAWBACK OF CONVENTIONAL •Hard Wired Logic Control
•In this, Contractor and relays together with timers and
SYSTEM
counters were used in achieving desired level of
Conventional equipment systems are prone to errors due
automation.
to the involvement of humans in the data collection and
•Bulky and complex wiring, Involves lot of rework to
processing using complicated mathematical expressions.
implement changes in control logic, the work can be
Thus what we require is a system that collects raw data,

Volume 2, Issue 5 September – October 2013 Page 170

 International Journal of Emerging Trends & Technology in Computer Science (IJETTCS)
Web Site: www.ijettcs.org Email: [email protected], [email protected]
Volume 2, Issue 5, September – October 2013 ISSN 2278-6856

started only when the takes is fully defined and this leads PLC Working
to longer project time. At the beginning of each cycle the CPU brings in all the
Electronics Control with Logic Gates field input signals from the input signals from the module
In this, Contactor and Relays together with timers and and store into internal memory as process of input signal.
counters were replaced with logic gates and electronic This internal memory of CPU is called as process input
timers in the control circuits. image (PII).User program (Application) will be available
Advantages in CPU program memory. Once PII is read, CPU pointer
•Reduced space requirements, energy saving, less moves in ladder program from left to right and from top
maintenance and hence greater reliability. to bottom. CPU takes status of input from PII and
•The Major Drawbacks processes all the rungs in the user program. The result of
•Implementation of changes in the control logic as well as user program scan is stored in the internal memory of
reducing the project lead- time was not possible. CPU. This internal memory is called process output
Programmable Logic Controller image or PIQ. At the end of the program run i.e., at the
In this, instead of achieving desired control and end of scanning cycle, the CPU transfers the signal states
automation through physical wiring of control devices, it in the process image output to the output module and
is achieving through program say software. further to the l.
Advantages
Reduced Space, Energy saving, Modular Replacement,
Easy trouble shooting, Error diagnostics programmer,
Economical, Greater life and reliability, The
Compatibilities of PLC’S, Logic Control, PID control,
Operator control, Signaling and listing, Coordination and
communication.

A. How PLC works

Basics of a PLC function are continual scanning of a
program. The scanning process involves three basic steps.
Step 1: Testing input status
First the PLC checks each of its input with intention to Figure: 1 PLC working
see which one has status on or off. In other words it
checks whether a switch or a sensor etc., is activated or I/O driver (SCADA) picks up PII and PIQ and transfers
not. The information that the processor thus obtains the image to database and this image is called driver
through this step is stored in memory in order to be used image. This driver image available in SCADA database is
in the following steps. used for graphical view of process monitoring from
Step 2: Programming execution operator station (OS) in the central control room.
Here a PLC executes a program instruction by instruction
based on the program and based on the status of the input A. Features of Allen Bradley PLC
has obtained in the preceding step, and appropriate action Using Allen Bradley 1000PLC Micrologix 1000PLC has
is taken. The action might be activation of certain outputs 20 digital outputs. The relationship with bit address to
and the results can be put off and stored in memory to be input and output devices is shown in the figure below.
retrieved later in the following steps.
Step 3: Checking and Correction of output status
Finally, a PLC checks up output signals and adjust it has
needed. Changes are performed based on the input status
that had been read during the first step and based on the
result of the program execution in step two – following
execution of step three PLC returns a beginning of the
cycle and continually repeats these steps.
Scanning time = Time for performing step 1+ Time for
performing step 2+ Time for performing step 3.

6. ALLEN BRADLEY PLC Figure. 2, I/O Pin Configuration of AB PLC

Programmable Logic Controller or PLC is an intelligent
system of modules, which was introduced in the control, The left side of the screen shows that eh project tree while
& instrumentation industry for replacing relay based logic the right side of the screen is the programming area.
[4]. Over a period of time, better I/O handling capabilities Either area can be increased in size, minimized, or closed
and more programming elements have been added along by left clicking the mouse on the appropriate symbol.
with improvement in communication. B. Interfacing

Volume 2, Issue 5 September – October 2013 Page 171

 International Journal of Emerging Trends & Technology in Computer Science (IJETTCS)
Web Site: www.ijettcs.org Email: [email protected], [email protected]
Volume 2, Issue 5, September – October 2013 ISSN 2278-6856

A. Basics
A SCADA system consists of a number of components
[7]. The RTU’s.Remote telemetry or terminal units. The
central SCADA master system.
Field Instrumentation
The SCADA RTU is a (hopefully) small ruggedized
computer, which provides intelligence in the field, and
Figure.3 Interfacing of PLC and SCADA allows the central SCADA master to communicate with
the field instruments. It is a stand-alone data acquisition
and control unit. Its function is to control process
equipment at the remote site, acquire data from the
equipment, and transfer the data back to the central
SCADA system.
FIX32 software enables you to configure a system
environment that provides: [3]
Supervisory control, batch processing, data acquisition,
continuous control, and statistical process control for
Figure 4. Interfacing to PLC industrial applications.

C. Connecting to the PLC 8. OPERATION

•Open a SCADA application
The project work consists of distribution of any kind of
•Create a tag of type I/O discrete, select the type as
liquid or semi-liquid into different plants from a main
discrete
buffer storage tank. This distribution takes place
•Select read only if you don’t want to force values to PLC.
automatically using the Programmable Logic Controller
Selecting read and write allows to the SCADA to read
(PLC). The main reservoir and the plant, where the
and force values to the PLC.
process is taking place are situated far apart physically
•Type an access name.• The access name can visualized
.All the process of this system is automatically done, like
as a gateway for a group of resources.
this sensing of the raw color material, opening and
•Most of PLC drivers communicate with SCADA package
closing of the valve (in tank), process taking in the plant
using DDE, DDE requires three parameters namely name
like heating and churning, and removal of the raw color
of the DDE server, topic name and item name. In case of
material. The successful operation with PLC have opened
reading a number of items from a particular PLC driver
possibilities for adapting automation commercially in all
application name topic name are common, so this
available plants The implementation of the process should
application name that is name of the DDE server and
provide the user with two options: 1-User can select one
Topic name combine to form an access name. Access
of the six colors which are shown on the HMI. 2-User
name is required to be defined only once then other items
can create his own color with his own ratio of the three
of driver can be accessed by using the Access name and
main colors. This process shown in block diagram and
item name. These details will be provided by the driver
flow chart
vendor or developer.
For the first case :selecting one of the six colors on the
•Click ok, the access name will be listed finally click
HMI, Precise ratios of the three main colors are required
done, then type the item name, click save to save the I/O
in order to form one of the colors to be chosen by user.
tags. Go to run time to communicate with PLC.
Thecolors will be selected in proper proportion through
the ratio control process. The mixture of colors will be
7. SCADA mixed in the reactor tank by mixer motor. Level will be
SCADA stands for Supervisory Control and Data controlled by ultrasonic type level.
Acquisition. As the name indicates, it is not a full control
system, but rather focuses on the supervisory level [2].
9. CONCLUSION
What is SCADA? It is used to monitor and control plant
The most important aspect of any color industry mixing
or equipment. The control may be automatic or initiated
which is main part which is controlled using PLC. The
by operator commands. The data acquisition is
method that has to be used relies on varied objectives like
accomplished firstly by the RTU’s scanning the field
superior quality, increased efficiency, high profit and
inputs connected to the RTU (it may be also called a PLC
other such points depending upon the purpose of the
– programmable logic controller.). This is usually at a fast
company that implies it. With the prime objective of
rate. The central host will scan the PTU’s (usually at a
catering to these necessities and the needs of the
slower rate). The data is processed to detect alarm
industrial sector, significance has been given here to
conditions, and if an alarm is present, it will be displayed
automation.
on special alarm lists.

Volume 2, Issue 5 September – October 2013 Page 172

 International Journal of Emerging Trends & Technology in Computer Science (IJETTCS)
Web Site: www.ijettcs.org Email: [email protected], [email protected]
Volume 2, Issue 5, September – October 2013 ISSN 2278-6856

This paper presented here has kept in mind, the ceaseless

changes that are relentlessly taking place in the
contemporary scenario of the industrial segment.
Emphasis has been given to the automation process that is
now rapidly taking its place in all plants across the globe.
The Paper has furnished itself to study the integral parts
of the entire process involved, their implementation
andthe problems that mayshow uphave also been given
their due importance. The future work deals with the
purification of water to the boiler and the air circulation
for the boiler to burn the fuel using sameautomation
technique. Making of product in industry is easy with the
help of PLC.

REFERENCES
[1] [1]Ezell, Barry, “Scenarios One and Two: Source to
Figure5: Block diagram of color making and mixing
No 1PS to No 1 Tank to No 2 PS to No 2 tank (High
process
level) for a Master-Slave SCADA System”, SCADA
Consultants, SCADA Mail List,
[email protected] (August 1997).
[2] Rockwell Automation SCADA System Selection
guide Allen-Bradley, Publication AG-2.1. 1998.
[3] Knight. U. “The Power System and its Operational
and Control Infrastructure in emergencies” from
contingency planning to crisis management.
[4] analysis of Fault-Tolerant systems, “IEEE
transactions on Computers”, vol.38, No.6, 1989.
[5] Gary Dunning, “Introduction to Programmable
Logic” Controllers, Edition third, 628 .
[6] Clarence A. Phipps, “Fundamentals of electrical
control”, Publisher The Fairmont Press, Inc.
1999,Edition2,illustrated,213,Page .162,164,165.
[7] Ramakant A. Gayakwad, “Op-Amps and Linear
Integrated Circuits”, Publisher PHI prentice hall
India, Fourth Edition, , Page no.438,439.
Figure6: SCADA Screen result

Prof. S. T. Sanamdikar is currently

working as Asso. Prof at PDEA’s College
of Engineering Manjari, Pune. He received
the B.E. degree in Instrumentation Engineering from
S.G.G.S. Institute of Engineering and Technology,
Nanded from Dr Babasaheb AMBEDKAR University,
Aurangabad and M.E. from S.G.G.S. Institute of
Engineering and Technology, Nanded. He is pursuing
Ph.D. at S.G.G.S. Institute of Engineering and
Technology, Nanded, in ECG ARRHYTHMIA
ANALYSIS. His area of interests includes Wavelet
Transform, Image and Signal Processing, Biomedical
Digital Signal Processing.

Volume 2, Issue 5 September – October 2013 Page 173

 International Journal of Emerging Trends & Technology in Computer Science (IJETTCS)
Web Site: www.ijettcs.org Email: [email protected], [email protected]
Volume 2, Issue 5, September – October 2013 ISSN 2278-6856

Figure7: Flow chart

Volume 2, Issue 5 September – October 2013 Page 174