Documente Academic
Documente Profesional
Documente Cultură
Smoke
&
Gas
detection
Monitoring
and
Control
using
PLC
His
unending
quench
for
maximizing
the
scope
and
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
Lastly we would like to offer our regards to all those who have supported
us in any respect during the completion of our project.
ABSTRACT
The Project is to study Smoke and Gas detector Systems with PLC
(Programmable Logic Control).
Smoke Detector System:
Smoke detector system is essential for Industrial and Commercial
facilities. It detects accidental fire and spray water on the source of fire to
quench it. They include different type of smoke detectors, both
addressable and conventional and Fire Alarm Control Panel (FACP). In
the current project in place of FACP, Programmable Logic Controller
(PLC) used for Logic development.
Gas Detector System:
Gas detector system is essential for detecting flammable and poisonous
gases
in
Industrial
facilities
and
HVAC
(Heating
Ventilation
Air
Conditioning) systems.
Programmable Logic Controller:
Programmable Logic Controller is a digitally operated electronic system,
designed
for
use
in
an
industrial
environment,
which
uses
for
implementing
specific
functions
such
as
logic
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
easily integrated into an industrial control system & easily used in all
their intended functions.
Incoming control signals, or inputs, interact with instructions specified
in the user ladder program, which tells the PLC how to react with the
incoming signals. The user program also directs the PLC on how to
control field devices like motor starters, pilot lights, & solenoids. A signal
going out of the PLC to control a field device is called an Output.
TABLE OF CONTENTS
CHAPTER
PAGE NUMBER
ACKNOWLEDGEMENT
ABSTRACT
Chapter 1: Introduction
1.1Project Overview
12
12
15
15
18
22
26
27
30
44
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
44
45
46
52
52
55
56
56
56
57
2.4.1 Sensitivity
57
2.4.2 Specifications
58
58
58
60
3.1 Introduction
60
3.2Programming Languages
63
67
69
73
77
4.2 Introduction
78
78
81
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
83
85
86
87
87
89
95
REPRESENTATION
5.1 Project PLC Programming Pictorial
101
Representation
CHAPTER 6: ADVANTAGES AND LIMITATIONS
106
6.1 Advantages
106
6.2 Limitations
107
6.3 Conclusion
108
BIBLOGRAPHY
109
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
LIST OF FIGURES:
Figure
Page number
Fig 1: Inside view of Smoke Detector
10
Fig 2: Observation Relays
11
Fig 3: Smoke Detector Installation
12
Fig 4: Installation and placement
14
Fig 5: Horn & Beacon
28
Fig: 6 Wiring Diagram
32
Fig: 7 Addressable FACP
33
Fig: 8 System Functions
37
Fig 9: Fire alarm panel, showing drill switch
38
Fig 10: Allen Bradley PLC Architecture
49
Fig11: Block Diagram
52
Fig 12: Project Perspective-1
53
Fig 13: Project Perspective-2
54
Fig 14: Wiring Diagram
55
Fig 15: LPG Gas Detector
57
Fig 16: PLC Rack
61
Fig 17: PLC Operatation
62
Fig 18: Basic Components of SFC Lanuguage
65
Fig 19: Basic Components of FBD Language
67
Fig 20: Timer & Counter
70
Fig 21: Three types of Logic representation
72
Fig 22: Positive Logic
74
Fig 23: AND Symbol
75
Fig 24: OR Symbol
76
Fig 25: Inverting Circuit
77
Fig 26: Reset Operation
77
Fig 27: Electrical Interlock Circuit
78
Fig 28: Symbol used Ladder Diagrams
80
Fig 29: Automatic Control of a pressurized water
82
tank
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
Fig
Fig
Fig
Fig
Fig
Fig
30:
31:
32:
33:
34:
35:
88
90
90
91
91
92
Capacitor
Fig 36: Full wave Rectifier
Fig 37: Project Model with PLC
Fig 38: Project Model View-1
Fig 39: Project Model View-2
Fig 40: PLC Trainer
Fig 41: Project Model View-3
Fig 42: Project Model View-4
Fig 43: Programming Screen Shot-1
93
95
96
97
98
99
100
101
102
103
104
105
Chapter1: Introduction:
1.1 Project Overview:
The Project is the study of Smoke and Gas detector systems with PLC
(Programmable Logic Controller).
The Project includes Smoke and Gas detectors, fan, pump, and solenoid
valve activation. The logic is developed in the Allen Bradley PLC
(Programmable Logic Controller).
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
It
includes
about
37 kBq or
1 Ci of
radioactive
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
10
alpha particles, which reduces the ionization and interrupts this current,
setting off the alarm.
An alpha emitter, has a half-life of 432 years. Alpha radiation, as
opposed to beta and gamma, is used for two additional reasons: Alpha
particles have high ionization, so sufficient air particles will be ionized for
the current to exist, and they have low penetrative power, meaning they
will be stopped by the plastic of the smoke detector or the air.
Obscuration is a unit of measurement that has become the standard
definition of smoke detector sensitivity. Obscuration is the effect that
smoke has on reducing sensor visibility; higher concentrations of smoke
result in higher obscuration levels.
Photoelectric
Beam
Aspirating
Laser
Commercial
smoke
detectors
are
either
conventional
or
analog
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
11
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
12
Several
specifications
methods
published
are
used
and
documented
by Underwriters
in
industry
Laboratories[12] Alerting
methods include:
Audible tones
85 dBA at 10 feet
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
13
In
new
construction,
minimum
requirements
are
typically
more
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
14
of the alarm will be reduced and may not wake some people. Some areas
also require smoke detectors in stairways, main hallways and garages.
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
15
There are three main types of gas hazard: Flammable, Toxic and
Asphyxiant
Flammable Gas Hazards
Combustion is a fairly simple chemical reaction in which oxygen is
combined rapidly with another substance resulting in the release of
energy. This energy appears mainly as heat sometimes in the form of
flames.
The
igniting
substance
is
normally,
but
not
always,
Flammable Limit
There is only a limited band of gas/air concentration which will produce
a combustible mixture. This band is specific for each gas and vapor and
is bounded by an upper level, known as the Upper Explosive Limit (or the
UEL) and a lower level, called the Lower Explosive Limit (LEL). At levels
below the LEL, there is insufficient gas to produce an explosion (i.e. the
mixture is too lean), whilst above the UEL, the mixture has insufficient
oxygen (i.e. the mixture is too rich). The flammable range therefore falls
between the limits of the LEL and UEL for each individual gas or mixture
of gases. Outside these limits, the mixture is not capable of combustion.
The Flammable Gases Data in section 2.4 indicates the limiting values
for some of the better-known combustible gases and compounds. The
data is given for gases and vapors at normal conditions of pressure and
temperature. An increase in pressure, temperature or oxygen content will
generally broaden the flammability range. In the average industrial plant,
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
16
there would normally be no gases leaking into the surrounding area or,
at worst, only a low background level of gas present. Therefore 5
Flammable Gas Hazards Flammable Limit There is only a limited band of
gas/air concentration which will produce a combustible mixture. This
band is specific for each gas and vapor and is bounded by an upper level,
known as the Upper Explosive Limit (or the UEL) and a lower level, called
the Lower Explosive Limit (LEL). the detecting and early warning system
will only be required to detect levels from zero percent of gas up to the
lower explosive limit. By the time this concentration is reached, shutdown procedures or site clearance should have been put into operation.
In fact this will typically take place at a concentration of less than 50
percent of the LEL value, so that an adequate safety margin is provided.
However,
it
should
always
be
remembered
that
in enclosed
or
17
rotten eggs smell of H2S. The measurements most often used for the
concentration of toxic gases are parts per million (ppm) and parts per
billion (ppb). For example 1ppm would be equivalent to a room filled with
a total of 1 million balls and 1 of those balls being red. The red ball
would represent 1ppm. More people die from toxic gas exposure than
from explosions caused by the ignition of flammable gas. (It should be
noted that there is a large group of gases which are both combustible
and toxic, so that even detectors of toxic gases sometimes have to carry
hazardous area approval). The main reason for treating flammable and
toxic gases separately is that the hazards and regulations involved and
the types of sensor required are different.
Hygiene Monitoring
The term hygiene monitoring is generally used to cover the area of
industrial health monitoring associated with the exposure of employees
to hazardous conditions of gases, dust, noise etc. In other words, the aim
is to ensure that levels in the workplace are below the statutory limits.
This subject covers both area surveys (profiling of potential exposures)
and personal monitoring, where instruments are worn by a worker and
sampling is carried out as near to the breathing zone as possible. This
ensures that the measured level of contamination is truly representative
of that inhaled by the worker.
1.3.2Typical Areas that Require Gas Detection
There are many different applications for flammable, toxic and oxygen
gas detection. Industrial processes increasingly involve the use and
manufacture of highly dangerous substances, particularly toxic and
combustible gases. Inevitably, occasional escapes of gas occur, which
create a potential hazard to the industrial plant, its employees and people
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
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Production Platforms
Refineries
Typical Gases:
Flammable: Hydrocarbon gases
Toxic: Hydrogen Sulfide, Carbon Monoxide
Typical Applications:
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19
Digesters
Plant sumps
H2S Scrubbers
Pumps
Typical Gases:
Flammable: Methane, Solvent vapors
Toxic: Hydrogen Sulfide, Carbon Dioxide, Chlorine, Sulfur Dioxide,
Ozone.
Boiler Rooms
Boiler Rooms come in all shapes and sizes. Small buildings may have a
single boiler whereas larger buildings often have large boiler rooms
housing several large boilers.
Typical Applications:
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
20
Hospitals
Hospitals may use many different flammable and toxic substances,
particularly in their laboratories. Additionally, many are very large and
have onsite utility supplies and backup power stations.
Typical Applications:
Laboratories
Refrigeration plants
Boiler rooms
Typical Gases:
Flammable: Methane, Hydrogen
Toxic: Carbon Monoxide, Chlorine, Ammonia, Ethylene oxide and
0Oxygen deficiency
Tunnels/Car Parks
Car Tunnels and enclosed Car Parks need to be monitored for the toxic
gases from exhaust fumes. Modern tunnels and car parksuse this
monitoring to control the ventilation fans. Tunnels may also need to be
monitored for the build up of natural gas.
Typical Applications:
Car tunnels
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21
Access tunnels
Ventilation control
Typical Gases:
Flammable: Methane (natural gas), LPG, LNG, Petrol Vapor.
Toxic: Carbon Monoxide, Nitrogen Dioxide
Principles of Detection
Many people have probably seen a flame safety lamp at some time and
know something about its use as an early form of firedamp gas detector
in underground coal mines and sewers. Although originally intended as a
source of light, the device could also be used to estimate the level of
combustible gases- to an accuracy of about 25-50%, depending on the
users
experience,
training,
age,
colour
perception
etc.
Modern
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
22
23
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
24
doesnt drift unlike catalytic detectors. And unlike catalytic types, the
detector doesnt need oxygen for operation,
Point infra-red gas detectors
Point detectors record the gas concentration at the detector location.
They need to be placed where a release of gas is considered possible.
They can be placed remotely and connected to the sampling location by
tubes, with air sucked across the detecting chamber. Consideration
needs to be given to the extra detection time added by the transit time
down the tube.
Example uses: Detection in confined spaces, specific locations, air inlets
etc.
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
25
Catalytic detectors rely upon burning gas in a sintered chamber. For this
reason they are only available as a point detector or as part of a multipoint aspirating system.
Various technologies are available chemical cell and semiconductor
point detectors; open path (Laser) gas detection is in development.
Many different types of gas can be detected. Cross-sensitivity to different
gases other than those being looked for needs to be given careful
attention.
Response times of detecting and testing frequencies need careful
attention.
Chemical cell types require sensor replacement at intervals determined
by the environment. Semiconductor cells are also affected by their
environment and may need to be kept awake by exposure to the detected
gas. New products are in development that are less susceptible to these
limitations.
Infra-red single gas open path detectors are at an advanced stage of
development. These offer the important advantages of fast response and
high reliability.
Example uses: H2S from sour oil wells or processing plant; carbon
monoxide from burning products and Co2 (Carbon Dioxide) build up
Calibration
The most common failure in catalytic sensors is performance degradation
caused by exposure to certain poisons. It is therefore essential that any
gas monitoring system should not only be calibrated at the time of
installation, but also checked regularly and re-calibrated as necessary.
Checks must be made using an accurately calibrated standard gas
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
26
mixture so that the zero and span levels can be set correctly on the
controller.
Codes of practice such as EN50073:1999 can provide some guidance
about the calibration checking frequency and the alarm level settings.
Typically, checks should initially be made at weekly intervals but the
periods can be extended as operational experience is gained. Where two
alarm levels are required, these are normally set at 20-25% LEL for the
lower level and 50-55% LEL for the upper level.
Today, there are a number of one-man calibration systems available
which allow the calibration procedures to be carried out at the sensor
itself. This considerably reduces the time and cost of maintenance,
particularly where the sensors are in difficult to get to locations, such as
an off-shore oil or gas platform. Alternatively, there are now some
sensors available which are designed to intrinsically safe standards, and
with these it is possible to calibrate the sensors at a convenient place
away from the site (in a maintenance depot for instance). Because they
are intrinsically safe, it is allowed to freely exchange them with the
sensors needing replacement on site, without first shutting down the
system for safety.
Maintenance can therefore be carried out on a hot system and is very
much faster and cheaper than early, conventional systems.
1.3.4 Location of Sensors
How many detectors do I need? and where should I locate them? are
two of the most often asked questions about gas detection systems, and
probably two of the most difficult to answer. Unlike other types of safety
related detectors, such as smoke detectors, the location and quantity of
detectors required in different applications is not clearly defined.
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
27
28
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
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Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
30
intervention
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
31
A Siemens MXL fire alarm control panel (top) and graphic annunciator.
A Fire Alarm Control Panel (FACP), or Fire Alarm Control Unit (FACU),
is the controlling component of a Fire Alarm System. The panel receives
information from environmental sensors designed to detect changes
associated with fire, monitors their operational integrity and provides for
automatic control of equipment, and transmission of information
necessary to prepare the facility for fire based on a predetermined
sequence. The panel may also supply electrical energy to operate any
associated sensor, control, transmitter, or relay. There are four basic
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
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Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
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Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
34
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
35
[1] [2]
Each device on a SLC has its own address, and so the panel knows the
state of each individual device connected to it. Common addressable
input (initiating) devices include
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
36
Smoke detectors
Responders
Switches
Flow control
Pressure
Isolate
Standard switches
Closing/opening doors
Mapping
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
37
Zones
Groups
outputs
than
the
programming
space
for
single
detector/input allows.
Boolean logic
This is the part of a fire panel that has the largest variation
between different panels. It allows a panel to be programmed to
implement fairly complex inputs. For instance, a panel could be
programmed to notify the fire department only if more than one
device has activated. It can also be used for staged evacuation
procedures in conjunction with timers.
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
38
Networking
More
recently,
some
panels
are
being
networked
with
Monitoring
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
39
These systems will generally have a top level map of the entire site,
with various building levels displayed. The user (most likely a
security guard) can progress through the different stages. From
top level site building plan floor plan zone plan, or however
else the building's security system is organised.
A lot of these systems have touch screens, but most users tend to
prefer a mouse (and a normal monitor), as it is quite easy for a
touch screen to become misaligned and for mistakes to be made.
With the advent of the optical mouse, this is now a very viable
option.
System functions
There are many functions on a fire alarm panel. Some of these are:
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
40
System reset
This resets the panel after an alarm condition. All initiating devices are
reset, and the panel is cleared of any alarm conditions. If an initiating
device is still in alarm after the system is reset, such as a smoke
detector continuing to sense smoke, or a manual pull station still in an
activated position, another alarm will be initiated. A system reset is often
required to clear supervisory conditions. A system reset does not usually
clear trouble conditions. Most trouble conditions will clear automatically
when conditions are returned to normal.
On UK and most US panels, a "Silence" or "Acknowledge" is usually
required before a "System Reset" can be performed.
Acknowledge
This function, also abbreviated to "ACK", is used to acknowledge an
abnormal situation such as an alarm, trouble or supervisory. The
acknowledge function tells the panel that building personnel or
emergency responders are aware of the alarm, trouble, or supervisory
condition. Acknowledging the alarm or trouble condition also normally
silences the panel's own sounder, but does not silence any Notification
Appliances.
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
41
Drill
Also known as "manual evacuation" or "evacuate". On panels that have
this function, the drill function activates the system's notification
appliances, often for purposes of conducting a fire drill. Using the drill
function, an alarm is normally not transmitted to the fire department or
monitoring center. However, building personnel often notify these
agencies in advance in case an alarm is inadvertently transmitted.
Walk test
Walk test allows the functional testing of the system's devices without the
assistance of additional people at the control panel itself. It is also
designed to allow initiating devices to be tested without setting off the
building's alarms. Most panels offer the option for a silent walk test (no
alarms activate) or an audible walk test (alarms activate for a brief period
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
42
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43
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
44
45
Pre alarm
This LED is often used in conjunction with a two-stage system, in which
the panel requires two devices to be activated (and/or a predetermined
time limit to run out after one device is activated) in order to go into full
alarm.[4] This is mostly used in areas where false alarms are a common
problem, or in large applications (such as hospitals) where evacuating
the entire building would not be efficient. The prealarm LED is lit when
one device has tripped. The prealarm LED may also be used if an analog
smoke detector registers low levels of smoke in the detection chamber,
but not enough to trigger a full alarm. [5] Depending on the system's
layout, the NAC's may or may not activate for prealarm conditions. In a
two-stage system, the NAC's are typically coded to a special first-stage
coding, or in some situations where a loud alarm signal could be
disruptive, chimes will activate. If there is a voice evacuation system, it
will usually instruct building occupants to await further instructions
while the alarm is being investigated.
Priority 2 alarm
Also known as "Security". This LED is common on top-of-the-line
intelligent panels. This LED can only activate if there is a secondary
device hooked into the "Priority 2 Alarm" terminals. This secondary
device could be a security system, building management system, or
another fire alarm control panel. Depending on how the panel is
programmed, the panel's alarms may or may not activate when a
condition like this is present.
Trouble
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
46
47
for
factory
automation,
process
control
and
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
48
crucial
process
parameters
and
adjust
process
by
person
unskilled
in
operating
computers.
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
49
began in the 1970s, and has become the most common choice for
manufacturing controls.
Programmable Logic Controllers have been gaining popularity on
the factory floor and will probably remain predominant for some
time to come. Most of this is because of the advantages they offer.
1.5.2 PLC Advantages and Disadvantages
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50
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
51
The Allen Bradley Programmable logic controllers help you in both time
and money saving, as well as offering you a faster start-up. Your new fast
start up time is a result of products that are pre-integrated--designed to
fit together like pieces of a well oiled puzzle. From the beginning to the
end of the operation, the maintenance will be far less and the need for
programming will be minimal.
Allen
Bradley
is
part
of
Rockwell
Automation
Integrated
Architecture and offers controllers that are suitable for drives, for
motion, and for process controlling. No matter what you need, if you have
to have high performance or value based in your programmable logic
controller system, you will find just the right controller with the Allen
Bradley programmable logic controllers.
The many different offerings from Allen Bradley-Rockwell Automation
Integration include the NetLinx, the Kinetix, and the Logix. All of these
will offer you maximum capabilities, easy use, reuse capacity of program,
flexibility in the communications system and fast easy use so that you
can spend less of your company's time and money on the entire setup
process.
Allen Bradley uses five different types of programmable logic controllers.
These different types of PLCs perform specialized functions.
Pico Controllers are simple, as well as flexible and small, performing
logic, counting, time and clock operations..
MicroLogix PLCs are a cost-effective solution for micro-control that will
expand as needed.
SLC 500s are small, modular programmable controllers that are chassisbased. It is often the choice for I/O and power supply functions.
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
52
PLC-5 is the most popular Allen Bradley PLC and can be found
worldwide, providing flexibility in networking, I/O and programming and
being suitable for a wide variety of applications. .
1758-RTU is a programmable logic controller designed for rugged and
harsh environments as a Remote Terminal Unit (RTU).
From conception to implementation, any Allen Bradley programmable
logic controller results in cost savings, increased productivity and
satisfied clients.
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
System Overview
53
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC