Basics of Automation

in
Steel melting shop (sms)
KAUSHAL CHOUHAN
AM(INSTRUMENTATION)
Levels of automation
 L2 Devlopment
PCs,app.server, Level 2
Clients

Layer3 Managed
Ethernet Switch

Layer2 Managed
Ethernet Switch

L1 HMI Layer2 Managed

Layer2 Managed
Client,Engg.Stations, Ethernet Switch
Ethernet Switch
BW laser Printers

Level1
PLCs Room
Tilting
RIO-Panels
Panels,MCCs,PCCs,VFDs,
DP-PA Link
Field Instruments(Level 0)
PLC,RIO PANEL & DP-PA Link
BASICS of PLC
• it is microprocessor based programming technique, which is used to perform many functions in
industrial process.
•It takes input instructions in form of ladder diagram or computer software instructions.
Specifications of PLCs & its Hardware
S.No PLCs Description

1. PLC1.1/2.1 – BOF tilting

2 PLC1.2/2.2- Gas Cooling, Collection & discharge

3 PLC 1.3/2.3 Bulk material system, flux and Ferro alloy addition

4 PLC 3.0 material handling and scrap

5 PLC 4.0 secondary dedusting

6 PLC 5.0 Primary Cooling Pump Houses

7 PLC 6.0 Secondary cooling pump houses + WTP

8 PLC7.0 for HMDS 1

9 PLC 8.0 HMDS 2
10 PLC 12.0 GRP
11 PLC 9.0 LF1
12 PLC 10.0 LF2
13 PLC 11.0 RH-OB
 Specifications of PLCs & its Hardware
• The PLCs of this project based on S7 400H(Hot Redundant) platform. The CPU series will used in CPU 417H ranges.
• Power Supply- Siemens PS 407 having range of AC 120-230 V.
• S7-400H CPU having 16 MB RAM(Expandable) and I/0 Capacity of 131072(Digital I/O) & 8192(Analog I/O).
• For high performance, fiber-optic cables are used to connect the two CPUs in a redundant automation system . Two
modules (sync modules) are to be inserted in each CPU for the fiber-optic connection.

•
Profibus (Process field bus)
•It is standard field bus communication in automation technology.
•Types:
1) Profibus DP(Decentralized Peripherals)-
it runs over two cored screened cable(Violet Sheathed) speed varies from 9.6Kbps to 12 Mbps and
RS485 physical layer.
it allows only 32 devices to be connected at once, more can be connected by using hubs &
repeaters.
2) Profibus PA(Process Automation)-
it is slower than DP and runs over two cored screened cable(Blue Sheathed) at fixed speed of 31.2
Kbps and uses IEC 61158-2 physical layer.
Profinet runs on industrial Ethernet (Speed up to 100Mbps) and basically used to link computer
system in a office or a network. Work on producer consumer technique(same as profibus master slave
technique)
RIO Panel
•SIMATIC ET 200M is the modular I/O station for the control cabinet with high density-channel
applications.
•Up to 12 multi-channel signal modules (e.g. 64 digital inputs) and function modules as well as
S7-300 communications processors can be used as I/O modules – the interface to the process.
Modules of RIO
•Profibus bus module
•Profibus Interface Module(IM 153-2)
•S7 300 series Analog/Digital I/O module
•HART Analog output module
•S7 300 series counter module
•Y link connector module- The Y link consists of two IM 153-2 interface modules and a Y coupler.
The Y link creates a gateway from a redundant DP master system to a unilateral DP master system.
•Optical Link Module(OLM)- it converts copper to fiber optic profibus.
•Modbus Communication Module CP341
•RS485 repeater-used to create a ’Star of buses’ topology for increasing availability of network.
 DP-PA link
•This unit consists of IM153-2 DP slave, one or more DP couplers and their PA instruments.
•It allows DP bus to run at its own speed, while subordinate PA line runs at its own without causing
mismatch.
• Also It can behave as master and slave network and via slave address, controllers and engg. Station
can access field devices.
Specifications
1. Bus Module
2. Interface Module- IM 153-2 is used as interfacing between RIO panel and DP/PA Link.
3. DP/PA Coupler- it is a physical link between Profibus DP and Profibus PA. Max. no. of DP/PA
couplers that can be connected to DP/PA link is 31 (i.e. max. field devices connected to DP/PA link
is 31).
4. AFD (Active Field Distributor)- PA field devices like instruments, sensor are connected to it.
5. Profibus PA Cable.
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