CHAPTER 1

INTRODUCTION
1.1 About RTPP
During the year 1985 the installed generating capacity of our state was 1963MW of
hydel units and 983MW of thermal units. Most of these units were located in the
northern half of the state. In view of the predominant hydel installation in the
Southern Region of the state, it is considered necessary to increase thermal generation
in the area thereby strengthening the base load capacity. Also the need for stable
power supply in the Rayalaseema region is considered a must, in view of the rapid
industrial growth envisaged in the region. Government of Andhra Pradesh has taken a
policy decision of locating a 420MW thermal power station in Rayalaseema region,
based on the water from the Mylavaram Dam on the Penneru River. Based on
Government Decision A.P.S.E.B has taken up 2 Nos. 210MW thermal units under
Rayalaseema Thermal Power Project (Stage-I). The project was approved by the
Planning Commission in March, 1988 at an estimated cost of Rs. 503.71 Cr. The
project helps improved the voltage profile in Rayalaseema region which is
economically backward and drought prone. It is built on a 2500 acre area acquired.
Water for the project is drawn from Mylavaram reservoir formed by Mylavaram dam
across River Penneru through a 22 KM long steel pipe line laid underground.
Rayalaseema Thermal Power Project is one of the major power generation facilities
developed in Andhra Pradesh to meet the growing demand for power. The Project
envisaged the installation of 5 x 210 MW coal based thermal generation units. The
first 210 MW unit came for commercial operation on 25-Nov-1994 and the second
210 MW unit on 30-Mar-1995.
1.2 Location
The project is located at a distance of 8 KM from Muddanur Railway Station of South
Central Railway on Chennai-Mumbai Railway Line. The site selected is at an
adequate distance from the populous towns and the land (2600 acres) is government
land not put to any use. The water requirement for the project is envisaged to be
supplied from the Mylavaram reservoir and Brahma Sagar reservoir. The project is
quite near to the existing railway line and transmission lines of the Andhra Pradesh
Grid.

Stage-I
Unit-I is synchronized to grid on 31st of March1994 while the Unit-II is synchronized
25th of February 1995. This stage-I is synchronized to the grid on 29th November of
1995.
Stage-II
Appreciating the prompt Completion of Rayalaseema Thermal Power Station Stage-I
project with the A.D.B. loan in a record time, the Director planning of C.E.A.
requested A.P.S.E.B. for preponing the Rayalaseema stage-II to the 8th plan from 9th
plan as many other projects planned for completion in 8th plan in the country were
not materializing. The A.P.S.E.B. agreed to it and the project was quickly approved
by CEA.
As an expansion to the existing stage-I A.P.S.E.B has taken up Rayalaseema Thermal
Power Project Stage-II by installation of two units of 210 MW thermal units adjacent
to the existing 2 units of 210 MW with estimated cost of the Project is Rs. 1640
Crores. PFC & REC has provided financial support for this stage. The annual coal
requirement of 2.06 million tones has been linked to Singareni collieries. Unit-III is
synchronized to grid on 25th of January 2007 while Unit-IV was synchronized on 20th
of November 2007.
Stage-III
During Dedication Programme of Unit-3, APGENCO has planned to take up one
210MW unit under Stage-III and one 600MW unit under Stage-IV as an expansion to
the existing Stage-II which is now under construction. Irrigation Department of AP
has allocated 1.4 TMC of water from Sri PothuluriVeeraBrahmam Reservoir via
G.O.Rt.No.183, on 29th march, 2010 for both Stage-III & Stage-IV.
Stage-IV (Under Construction)
APGENCO has taken up one 600MW unit as Stage-IV with an estimated cost of
Rs.3525Cr. M/s Power Finance Corporation Ltd. agreed to sanction loan of
Rs.2423Cr. on 19th of March 2010. Ministry of Coal allocated 2.31mtpa long term
coal linkage from MCL for 600MW Unit. MOC has been addressed for additional
quantity of 1.2mtpa required for 600MW.Additional coal linkage is awaited.
Purchase Order issued on 14-Oct-2010 to BHEL for BTG package for Rs.1445 Cr.
And another P.O. issued on M/s Tech Pro Systems Ltd for executing BOP works.

1.3 Coal to Power

Steam power plants basically operate on the Rankin
cycle shown in Fig1.1. Rankin cycle is a model that
is used to predict the performance of steam turbine
systems. It is an idealized thermodynamic cycle of
heating engine that
converts heat into mechanical energy. The heat is

Fig.1.1 Rankin cycle

usually supplied to a closed loop which uses water as working fluid. Coal is burnt in a
boiler which turns water into steam. The steam that produced form boiler is enfettered
into super heater which is heated at a temperature of 510. From the super heater the
steam is utilized for driving the turbines and the output of the turbines which is
Mechanical energy is given to the generator as the input and the power is delivered
from the Generator. It is given to the bus bars and transmitted over the transmission
lines to the load centers.
1.4 Description of coal plant
In the marshalling yard of Rayalaseema Thermal Power Station, coal loaded Broad
Gauge open wagons will be unloaded in to hoppers by two nose side discharge wagon
tipplers working on the main track. Side arm charges have been provided for each of
the wagon tipplers to work as a wagonmarshalling machine. The charger is mounted
alongside the main rail-track and runs on its own track parallel to main track to
prevent the roll-track of wagons on to tippler platform during tipping cycle. Clickingstops are provided both on inhaul and out haul side of main rail track .Wagon tipplers
have integral type-weighbridges for weighing wagons. From R.C.C. made hoppers
beneath tippler, coal will be replaced by two Vibrating feeders VF-1 to VF-2 and will
discharged to conveyor nos. 3A, 3B from the hoppers.
Table 1.1 Wagon Tippler Types
Type of Wagon
BOX
BOXN.MKD.II
BOXN
BOXNHA
BOZ
OZ
O

Height
3161
3225
3735
3450
3154
3037
2836

Width
3136
3200
3136
3200
2926
3136
3055

Length
14082
10715
10715
10713
13192
14740(PAIR)
14428(PAIR)

1.5 Wagon Tippler

Wagon tipplers are used to discharge broad
gauge open rail wagons. They have a rail
table mounted on a rotary support structures
which can lift and tilt wagons to an angle of
about 135 at various processing plants such
as power, steel, cement and for relocating
the bulk material like core,

Fig.1.2 Wagon tippler

Iron- ore, lime. A Rota side wagon tippler has a variable size domain, ranging from 90
to 110 tones shown in Fig1.2. These are different kinds of wagons of variable height,
width and length. However they can be handled skillfully by the Rota side wagon
tippler manufacture by TRF. Over 60 wagon tipplers manufacture by the company
provide trouble free service to customers across India. These tipplers have the
capability to unload 20wagons per hour, making this machine sought after and
dependable equipment for handling bulk material.
1.6 Side Arm Charger
The side Arm charger runs on its own set
of rails beside the tippler rail track and is
parallel to it. It is fitted with an extended
arm at its outer end which is an
automatic coupler. It couples to the front
of the wagon to draw a single loaded one
to position on to tippler platform, or to

Fig.1.3 Side arm charger

Draw the entire rake of loaded wagons. It also has got a pusher pad mounted on
forward face of its arm by which it can push on the rear of an empty wagon already
being unloaded by the wagon tippler. The arm is capable of being raised retracted to
clear the tipper structure with wagon on to it during tipping operation and can move in
to position between tipping cycles.
1.7 Dust Suppression System
The dust suppression system at wagon tippler employs the principle of spraying
chemical solution on the dust generation points either side of hopper and top of
wagon. The sprays at these locations start at different points of time with the help of
4

solenoid valves which are controlled by

timers. Water is received in a 4.5m
capacity RCC tank near wagon Tippler
Complex. MST compound is mixed with
water at the

outlet of feed water pump

in the ratio of 1:3750(chemical: water by

weight). This solutions thus formed is
Fig.1.4 Dust Suppression system

stored in a solution tank of capacity 470lts.

Solution pumps deliver this solution to respective wagon tipplers for spraying on
either side of the hopper.
1.8 Programmable Logic Controllers
A programmable logic controller is a digital computer used for electromechanical
processes, such as control of machinery on factory assembly lines, amusement lights,
or lighting fixtures and in many industrial machines such as packaging and
semiconductor machines. Unlike general-purpose computers, these are designed for
multiple inputs and output arrangement, extended temperature ranges, immunity to
electrical noise, and resistance to vibration and impact. Programs to control machine
operation are typically stored in battery-backed or non-volatile memory. A PLC is an
example of a real time system since output results must be produced in response to
input conditions within a bounded time, otherwise unintended operation will result.
1.8.1 Inputs and outputs of PLC
Inputs:
Auxiliaries.
On and off Push Buttons.
Outputs:
Lamps & Machines
1.8.2 Advantages of PLC

Reduced space.

Energy saving and easy of maintenances.

Modular replacement.

Easy trouble shooting.

5

CHAPTER 2
WAGON TIPPLER AND SIDE ARM CHARGER OPERATION
2.1 Description of Wagon Tippler and Side Arm Charger
Side discharge wagon tippler is suitable to handle BOXN MARK-II, BOXN,
BOX/BOX C, O TYPE IN PAIR wagons. The weigh bridge is equipped with an
indicator, recorder for printing gross & tare weights on internal paper roll.
The angle of tip achieved by the tippler is approximately 1500 & 00angle of the side of
the wagon if operates automatically at the following time cycle.
Table 2.1 Wagon Tippler timing cycle
-

Placement of Wagon
Weighing of wagon
Tippling operation
Pause
Return
Weighing
Total

59 seconds
46 seconds
5 seconds
5 seconds
29 seconds
10 seconds
144 seconds

2.2 Tippling operation

The wagon is pushed on to the tippler platform ejecting any emptied wagon
previously occupying it & is then weighed. There after the rotation commences, the
rail platform is lifted from its supports and as a result of the offset pivot, the wagon
tilts slowly until it rests against the longitudinal side beam. The rotation continues &
before the platform has attained 900 the tippler top clamp beams clamp the top of the
wagon with the help of a hydraulic cylinder, thus holding the wagon.
When the platform has rotated by approximately 1500 the fully tipped position is
reached, and the tippler halts. After a short pause to allow the contents of the wagon
to be discharged the tippler rotates in the opposite direction &returns the now empty
wagon which is then weighed & waits ejecting by the arrival of the nextwagon. The
equipment is designed to operate on 415V, 3phase, 50Hz supply.
2.3 Tippler parts
The tippler arrangement mainly comprises of the platform, end frames & pedestal
bearings, tippler drive, side beam and limit switches.

Platform:
The platform is a bridge shaped structure which carries a section of the rail track
through the installation. It has a length sufficient to accommodate the wagons to be
tipped. At rail level, the platform rests directly on the tippler foundations but it is
lifted off by the weigh bridge structure, for weighing operation or rail table supports
and the end frame toe rollers for the tipping operation.
End Frames and Pedestal bearings:
The end frames are heavy steel structures, roughly semicircular in shape, which rotate
on pedestal bearings located at above & frame side of the platform. When rotated
they pick up the platform with the wagon on it, which is inverted over the concrete
hoppers so that the contents are discharged. Reversal of the rotation then returns the
platform& wagon to rail level. The end frames are counter-weighed to balance part of
the weight of the wagon & platform.
End Frame drive:
The drive shaft carries a rack pinion, which engages with racks mounted to the
periphery of both the end frames. The shaft is driven by an electric motor, through
helical gear box & spurs gearing. The arrangement provides a means of rotating the
end frames, as described above. The drive assembly incorporates electromagnetic
brake automatic in operation, which holds the end frames against any movement
except that provided by the electric motor.
Side beam:
This is an arrangement of transverse & longitudinal beams, which support the weight
of the wagon during the tipping operation & so prevent it from falling off the
platform. The side beam is directly supported on the end frames.
Tippler Drive:
It should be required to disconnect the tippler-driving shaft, first it need to bring the
tippler to a state of balance, otherwise the machine will swing rapidly upon its pivots
as soon as the coupling bolts are removed. To balance the tippler, release the tippler-

drive brake by hand and let the machine turn until it is in equilibrium, where upon the
shaft may safely be disconnected.
2.4 Necessary working conditions of wagon tippler
a. Overrun limit switch
The operating leveler of this switch is activated by twin-strikers mounted on an
extension of the tippler pivot shaft.
Operation of the switch

Rotate the tippler to its normal TIPPED position.

Set one striker so that any further rotation of the tippler in the TIPPED
direction will trip the switch.

Rotate the tippler to its normal DOWN position.

Set remaining striker so that any further rotation in the DOWN direction
will trip the switch.

To reset manually

Release the hydraulic brake of the tippler drive-unit & let the tippler rotate by
gravity to within the limit of the auxiliary current gear limit switch.

Actuate by hand the operating leveler of the overrun limit switch.

b. Auxiliary current gear limit switch

Auxiliary current gear limit switch is coupled with pinion shaft. It consists of various
cams, which not only dictates the limit positions of the drive, but also carries out
switching duties at points between the extreme positions. These cams are adjustable
and shall be set manually considering end points of the operation. This limit switch
consists of gears, which in turn operates cams. The ratio gears are selected such that it
fulfills total travel of drive well within limits.
c. Photo cell
It consists of two components mainly transmitter and receiver. Transmitter at the rail
track and receiver at the top line. If there is any interruption in signal between
transmitter and receiver the operation haults .The interrupt may be due solid particles

or dust particles. So even small dust particles may cause interruption of the signal and
leads to tippling failure.
d. Weighing the loaded wagon
If weigh bridged is installed with the tippler, weighment of loaded wagon is to be
carried out as described in the weighbridge manual separately.
e. Tippling the wagon
After weighment of the loaded wagon, press & release the TIP push button. The
tippler along with loaded wagon rotates empties & wagon at its full tipping angle and
returns automatically to its normal rail level & stops.
f. Weighing the tippled wagon
Weighment of empty wagon has to be done as described in the weighbridge manual
separately.
2.5 Emergency condition
a. Making an emergency stop:
Press & release the STOP push button, during cycle of operations of wagon tippler
to stop the tippler operation during emergency. While tippler is rotating either in tip
direction or return direction, the tippler stops immediately.
b. Completing an interrupted cycle:
The wagon tippler stops in between during its cycle of operation, if emergency stops
push button is operated or due to power failure. Such incomplete cycle has to be
completed first to continue further continuous operations.
If the tippler was stopped during its return cycle, press & release its RETURN,
push button. The tippler returns to rail level & stop.
If the tippler was stopped in forward TIP direction or while the wagon was getting
emptied, press & release the RETURN push button. The tippler returns to rail level
& stops. Next, press the TIP push button for normal automatic tipping cycle.
The tippler should not be operated with inching motion as it can cause damage to
motor.

2.6 Charger Drive

Variable displacement A4VG180 pump is used for hydro motor and control through
amplifier and potentiometer to obtained desired flow from the system. For coupler
released system, oil flow is available from boost pump of A4VG180 pump. System is
equipped with hand pump, float switches, return line filters, air oil cooler etc., for
safety and proper operate of the system.
Charger drive System:
As soon as electric motor TP No.5 is switched on, boost pump of A4VG180 will start
delivering oil. Boost pump will fill up complete pipe lines, pump housing and
maintain 25 bar pressured in the line. Excess oil will return to the tank through boost
pressure relief valve through air oil cooler TP No.26 and return line filter TP No.28.
Boost pump filling oil through filter to ensure supply of cleaned oil into the main
pump.
Charger Drive Operation:
A rake (train) of 20 nos. of eight wheeler loaded wagons is pushed by locomotives on
tippler track on inhaul side such that first wheel of leading wagon is placed at inhaul
waiting position. Now locomotive is un-coupled from rake and goes back to bring
another rake of wagons. The side arm charger arm is lowered in front of leading
wagon through hydraulic cylinder about 2 meters away from the leading wagon. The
charger moves with fast acceleration up to slow speed towards leading wagon, till
charger coupler engages with coupler of leading wagon automatically and stops in
position. Mechanical stopper provided on inhaul side of wagon tippler are normally in
applied condition. Before the rake of wagons is pulled further, the mechanical
stoppers on inhaul side are opened automatically. The whole rake is pulled by side
arm charger with slow accelerations up to forward top speed.
Also the whole rake is stopped by side arm charger with slow deceleration & after
stopping the rake of wagons the leading wagon is decoupled manually from rake.
Mechanical stoppers on incoming side of wagon tippler closes automatically after
wagon passes through stopper. For central location indication, wagon on table limit
switch & groove is provided on rail at tippler table.

10

Also, during placement of loaded wagon the charger pushes previous empty wagon
on rail table through buffer provided exactly opposite to coupler. The centre
placement of loaded wagon tippler table is governed by fourth wheel position from
centre line of tippler at 5400mm for Box wagon and at 4262mm for Box N wagons.
After placement of wagon on tippler table, the sidearm charger arm coupler is
uncoupled by hydraulic cylinder & wagon is disconnected from arm coupler.
The side arm charger moves further with fast acceleration up to forward top speed,
after a pause with arm in lowered position, pushing empty wagon or rake of previous
empty wagons by buffer up to outhaul RETURN POSITION of side arm charger,
clearing rail table area for tippler to tip.
As soon as wagon is uncoupled from side arm charger coupler, gross weighing of
loaded wagon is carried out by weighbridge provided underneath rail table and
recorded automatically.
As soon as weighing is over and side arm charger reaches outhaul RETURN
POSITION, the rotation of tippler rail table starts. The hydraulic clamps start
clamping at different angle for different wagons and holds wagon firmly on tippler
table. Before wagon is clamped the rail table starts tilting towards side beam in the
direction of rotation and resets on the side beam pads. After the wagon is tipped at
1500 max & brought back to its initial position with empty wagon, tear weight of
wagon is recorded through load cell weighing bridge which in turn gives net content
discharged to hopper[1].
During this period the arm of the side arm charger at out haul RETURN POSITION
gets raised to 800 from horizontal position by hydraulic cylinder & charger travels
back with fast acceleration up to return top speed towards inhaul WAITING
POSITION stopping with fast deceleration about 2mtrs. Distance away from next
leading wagon coupler. Here arm gets lowered to horizontal & travel further towards
next leading wagon tip engage & pull further for next cycle of operation.

11

CHAPTER 3
PLC AND ELECTRONIC CARDS
3.1 Programmable Logic Control
Control engineering has evolved over time. In the past, humans were controlling the
systems. More recently electricity has been used for control and early electrical
control was based on relays. These relays allow power to be switched on and off
without a mechanical switch. It is common to use relays to make simple logical
control decisions. The development of low cost computer has brought the most recent
revolution, the Programmable Logic Controller (PLC). The advent of the PLC began
in the 1970s, and has become the most common choice for manufacturing controls.
PLCs have been gaining popularity on the factory floor and will probably remain
Predominant for some time to come. They are used mostly because of the advantages
they offer.

Cost effective for controlling complex systems.

Flexible and can be reapplied to control other systems quickly and easily.

Computational abilities allow more sophisticated control.

Trouble shooting aids make programming easier and reduce downtime.

Reliable components make these likely to operate for years before failure.

3.2 Ladder Logic

Ladder logic is the main programming method used for PLCs. As mentioned before,
ladder logic has been developed to mimic relay logic. The decision to use the relay
logic diagrams was a strategic one. By selecting ladder logic as the main
Programming method, the amount of retraining needed for engineers and trades
people was greatly reduced.
Modern control systems still include relays, but these are rarely used for logic. A relay
is a simple device that uses a magnetic field to control a switch, as pictured in Fig.
3.1. When a voltage is applied to the input coil, the resulting current creates a
magnetic field. The magnetic field pulls a metal switch (or reed) towards it and the
contacts touch, closing the switch. The contact that closes when the coil is energized
is called normally open. The normally closed contacts touch when the input coil is not
energized. Relays are normally drawn in schematic form using a circle to represent
12

the input coil. The output contacts are shown with two parallel lines. Normally open
contacts are shown as two lines, and will be open (non-conducting) when the input is
not energized. Normally closed contacts are shown with two lines with a diagonal line
through them. When the input coil is not energized the normally closed contacts will
be closed (conducting).

Fig.3.1 A simple relay controller

Relays are used to let one power source close a switch for another (often high current)
Power source, while keeping them isolated. An example of a relay in a simple control
application is shown in Fig 3.2. In this system the first relay on the left is used as
normally closed, and will allow current to flow until a voltage is applied to the input
A. The second relay is normally open and will not allow current to flow until a
voltage is applied to the input B. If current is flowing through the first two relays then
current will flow through the coil in the third relay, and close the switch for output C.
This circuit would normally be drawn in the ladder logic form. This can be read
logically as C will be on if A is off and B is on.
The example in Fig 3.1 does not show the entire control system, but only the logic.
When we consider a PLC there are
inputs, outputs, and the logic. Fig 3.2
shows a more complete representation
of the PLC. Here there are two inputs
from push buttons. We can imagine the
inputs as activating 24V DC relay coils
in the PLC. This in turn drives an
output relay that
Fig.3.2 A PLC illustrated with relays
13

switches 115V AC, which will turn on a light. Note, in actual PLCs inputs are never
relays, but outputs are often relays. The ladder logic in the PLC is actually a computer
program that the user can enter and change. Notice that both of the input pushbuttons
are normally open, but the ladder logic inside the PLC has one normally open contact,
and one normally closed contact. Do not think that the ladder logic in the PLC needs
to match the inputs or outputs. Many beginners will get caught trying to make the
ladder logic match the input types.
Many relays also have multiple outputs (throws) and this allows an output relay to
also be an input simultaneously. The circuit shown in Fig 3.3 is an example of this, it
is called a seal in circuit. In this circuit the current can flow through either branch of
the circuit, through the contacts lapelled A or B. The input B will only be on when the
output B is on. If B is off, and A is energized, then B will turn on. If B turns on then
the input B will turn on and keep output B on even if input A goes off. After B is
turned on the output B will not turned off.

Fig.3.3 A seal-in circuit

3.3 Programming
The first PLCs were programmed with a technique that was based on relay logic
wiring schematics. This eliminated the need to teach the electricians, technicians and
engineer

how

to

program

computer, but this method has

stuck and it is the most common
technique for programming PLCs
today. An example of ladder logic
can be seen in Fig3.4. To interpret
this diagram imagine that the
power is on the vertical line on
the left hand side.

Fig.3.4 A simple ladder logic

14

On the right hand side is the neutral rail. In the Fig there are two rungs, and on each
rung there are combinations of inputs (two vertical lines) and outputs (circles). If the
inputs are opened or closed in the right combination the power can flow from the hot
rail, through the inputs, to power the outputs, and finally to the neutral rail. An input
can come from a sensor, switch, or any other type of sensor. An output will be some
device outside the PLC that is switched on or off, such as lights or motors. In the top
rung the contacts are normally open and normally closed. This means if input A is on
and input B is off, then power will flow through the output and activate it. Any other
combination of input values will result in the output X being off.
The second rung of Fig 3.4 is more complex, there are actually multiple combinations
of inputs that will result in the output Y turning on. On the left most part of the rung,
power could flow through the top if C is off and D is on. Power could also (and
simultaneously) flow through the bottom if both E and F are true. This would get
power half way across the rung, and then if G or H is true the power will be delivered
to output Y. Structured Text programming has been developed as a more modern
programming Language. It is quite similar to languages such as BASIC[2].

Fig.3.5 An example of sequential function chart

3.4 PLC connections
When a process is controlled by a PLC it uses inputs from sensors to make decisions
and update outputs to drive actuators, as shown in Fig 3.5. The process is a real
process that will change over time. Actuators will drive the system to new states (or
modes of operation). This means that the controller is limited by the sensors available,
if an input is not available, the controller will have no way to detect a condition. The
control loop is a continuous cycle of the PLC reading inputs, solving the ladder logic
and then changing the outputs. Like any computer this does not happen instantly. Fig

15

3.6 shows the basic operation cycle of a PLC. When power is turned on initially the
PLC does a quick sanity check to ensure that the hardware is working properly. If
there is a problem the PLC will halt and indicate there is an error.
For example, if the PLC backup battery is low and power was lost, the memory will
be corrupt and this will result in a fault. If the PLC passes the sanity checks it will
then scan (read) all the inputs. After the inputs values are stored in memory the ladder
logic will be scanned (solved) using the stored values - not the current values. This is
done to prevent logic problems when inputs change during the ladder logic scan.
When the ladder logic scan is complete the outputs will be scanned (the output values
will be changed). After this process the system goes back to do a sanity check, and the
loop continues indefinitely. Unlike normal computers, the entire program will be run
every scan. Typical times for each of the stages are in the order of milliseconds

Fig.3.6. A separation of controller and process

Fig.3.7 The scan cycle of a PLC

3.5 Ladder Logic Inputs
Inputs are easily represented in ladder logic. In Fig 3.7 there are three types of inputs
shown. The first two are normally open and normally closed inputs, discussed
previously. The IIT (Immediate Input) function allows inputs to be read after the input
scan, while the ladder logic is being scanned. This allows ladder logic to examine
input values more often than once every cycle
16

Fig.3.8 Ladder logic inputs for PLC

3.6 Ladder Logic Outputs
In ladder logic there are multiple types of outputs, but these are not consistently
available on all PLCs. Some of the outputs will be externally connected to devices
outside the PLC, but it is also possible to use internal memory locations in the PLC.
Six types of outputs are shown in Fig 3.8. The first is a normal output, when
energized the output will turn on, and energize an output. The circle with a diagonal
line through is a

normally on

Fig.3.9 Ladder logic outputs

When energized the output will turn off. This type of output is not available on all
PLC types. When initially energized the OSR (One Shot Relay) instruction will turn
on for one scan, but then be off for all scans after, until it is turned off. The L (latch)
and U (unlatch) instructions can be used to lock outputs on. When an L output is
energized the output will turn on indefinitely, even when the output coil is deenergized. The output can only be turned off using a U output. The last instruction is
the IOT (Immediate Output) that will allow outputs to be updated without having to
wait for the ladder logic scan to be completed.
17

3.7 Applications of PLC Systems

In Industry, there are many production tasks which are of highly repetitive
nature although repetitive and monotonous, each stage needs careful attention
of operator to ensure good quality of final product.
Many times, a close supervision of process causes high fatigue on operator
resulting in loss of track of process control.
Under all such conditions we can use PLCs effectively in totally eliminating the
possibilities of human errors.
3.8 Energy Savings
In traditional pumping and HVAC applications, the flow of a system was reduced or
increased by the opening or closing of valves and dampers. This method of flow
control was reliable and worked well, however significant energy was required for the
system. In these systems, although demand decreased, the electric motor remained at
full speed requiring excessive energy costs. With the addition of a variable frequency
drive, flow control is reached by slowing the electric motors speed rather than
closing dampers and valves. This method of control often saves significant amounts
of energy where the VFD will be paid for in six twelve months alone on saved
energy! The annual cost of energy in an AC motor is as follows:
Energy Cost = HP * .746 * (hours used) *(cost of power)/motor efficiency
In a pumping or HVAC system, the flow of a system is reduced linearly as the speed
is reduced. However, the power is reduced by the cube as shown in the following
curves. Since most systems are designed for worst case scenarios and very rarely
operate at peak levels, the addition of a VFD can result in substantial energy savings.
Notice that a small reduction in speed equates to a large reduction in the power
requirement of the variable torque load. From the graphs above it can be shown that a
20% reduction in speed can result in 50% less power consumption. This can result in
tremendous energy savings for the typical system.

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Fig.3.10 Flow Vs speed

Fig.3.11 Power Vs speed

3.9 Electronic Card

The electronic card is an electrical amplifier for the control of proportional valves
without electrical feedback. The amplifier VT3600 is suitable for the control of pilot
operated proportional directional valves & direct operated proportional pressure valves
without electrical position feedback[3].
Characteristics:

Four command values adjustable with potentiometers.

Four command value call-ups with LED display.

Differential input,Step function generator

Ramp generator with five ramp times.

Two pulsed current output stages.

Polarity protection for the voltage supply.

F

Fig.3.12 An electronic card

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3.9.1 Functional Description

With the command value inputs 1to4 command values can be called up by operating
the corresponding relays (k1 to k4). The command value voltage is either given
directly through the controlled voltage 9V of the power supply or via an external
command value potentiometer. For this inputs 9V = 100% is valid. If these four
command value inputs are directly connected to the controlled voltage 9V four
different command values can be set at potentiometer R1 to R4. When using external
command value potentiometers at these inputs the internal potentiometers also function
as weakness or limiters when these are not set to maximum.Which command value is
momentarily called up is indicated by the LEDs H1 to H4. if more than one command
value is called up simultaneously the input with the highest number has priority.
Examples
If command value 1 & command value 3 are activated simultaneously the
command value 3 becomes effective.

A further output of the card provides a supply voltage for the command value
call-ups which can be switched over from +9V to -9V with the relay K6.

Each one of the four commands call-up values has an adjustable ramp time
allocated. If no command value is called up the ramp time t5 becomes
effective.

All relays on the card are switched with 24V DC.

Additionally, the direct command value input 5 is available for the input
voltage 0 to 6V. Valid is6V.

The command value input 6 is a differential input (0 to 10V).If the command value is
presented by a separate electronics with a different reference potential this input must
be taken care that both signal lines are either separated from or connected to the input.
All command values are summated with the correct value and sign before they are
connected further. The added ramp generator produces a ramp like output signal. The
time constant can be set with the potentiometers t1 to t5. The ramp type given
refers to command value jump of 100% & can be according to setting through the
selection via jumpers approximately 1s to 5s, if a command value jump smaller than
100% is switched to the input of the ramp generator the ramp time shortens
approximately.

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By switching the relay K5 or through an external bridge the ramp time is set to its
minimum value (approx. 30 ms).The output signal of the ramp generator runs parallel
to the summator & the step function generator produces a polarity dependent constant
step signal with the command value voltage which is added to the output signal of the
ramp generator. This step function causes the rapid traveling across the overlapping
area of the valve. The output signal of the summator is command current value and is
led to two current output stages & to the test point w on the front plate of the card. A
voltage of 6V at current valve test points corresponds to the command valve 100%. A
positive command valve signal at the input of the amplifier controls the output states
of the solenoid B, a negative command value signal the output stage for solenoid
A. If the command value signal is smaller than +-1% a pilot current of 20ma flows
through both solenoids. The actual values of current through the two solenoids can be
measured separately at the test point IA (solinoid1) IB (solenoid B). Here a current
of 800ma corresponds to a voltage of 800V. LED H11 lights up when the syste4m is
powered up.
LED H12 (ready for operation) lights up to indicate trouble free operation as long as
the internal power supply (9V) is functio0ning properly. There is no short-circuit in the
solenoid lines.
In the event of a fault, both output stages are immediately de-energized & the signal
ready for operation 9lED H12 is cancelled. Once the fault has been cleared, the
amplifier card is immediately operable & LED H13 lights up again.

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CHAPTER 4
TIPPLING OPERATION
4.1 Tipping operation
As soon as the loaded wagon is kept on the main central position by the SAC, the
tippling process starts with weighing the loaded wagon which is on the platform by
the weighing bridge. The relays or the Bits that are to be energized to release the
breaks of the hydraulic motor to start the tipping process is B3:10(0) which is
energized only when the enough pressure is applied to the clamps of the tippler &
along with this the relays that are to be energized to start the process.
The tip push button in the control desk is operated by the operator with which the
process starts, i.e. the inputs to the PLC are auxiliary gear limit switch SNRL limit
switch and system stop Bit B3:9(2) is to be energized and all the photo cell placed at
either ends of the tippler should be cleared and it should be seen that the wagon is at
central position exactly without any over traveling which is examined by the O.T.L.S
& this also should be energized with which the tippler return interposing relay i.e.
output relay 0:8(2) is energized as shown in Fig 4.1.

Fig.4.1 Ladder diagram for tippling

One the motor are to be started i.e. all the three rotors used for the tipping which are
also handled by the relays and along with this the motor should be slowed down (or)
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change its speed automatically at some conditions which is controlled by the LRSC
B3:9(14) Bit this also energized with all these relays energized the wagon tippler
tipping Bit B3:10(0) is energized and the process goes on.
All the above relays are energized at a time if any one of the relay is not energized
Emergency stop push button B3:1(0) series with the wagon tippler interposing relays
0:8(1) will energized & the tippling. During the tippling the motor will run at high
speed from 10 to 150 but after the 150 the motor automatically slows down and the
tippling is done without any accidents taking place.
4.2 Tippler reverse operation
After the tippling of the wagon which is lifted by the empty wagon is to be returned
and placed at the normal central position which is called the tippler reverse operation.
For the tippler reverse operation to start the BIT B3:10(1) should be energized. To the
BIT B3:10(1) get energized, firstly the return Push Button on the control desk is
energized i.e. (I:3(15) ), TIP-1 manual mode BIT (B3:9(13)) is to be energized along
with the Auxiliary Gear Limit RTL (Rail Level Tippler) BIT I:3(0) is energized as
soon as all these Input Bits get energized the output bits i.e., the Interposing relay
O:8(1) 3R(2) (return interposing relay) &the tippler motor relay I:3(8) are energized
& also the motor break I:3(7) is released and the electromagnetic relay is operated are
energized with the tip stop P.B&C.D I:4(0) and the Bit B3:10(1) which is the main Bit
that is to be energized to continue the tippler return operation is energized.
The Auxiliary Gear Limit Switches energized above are for the variations of the speed
of the motor during return process at 10 angle the tippler returns with the same speed
at the 180 at10 and slows down after 10 to place the wagon slowly on the plat.
As soon as the return process is completed & wagon is in the normal position then the
emptied wagon is weighted by the weighing bridge to find the resultant weight of the
coal transported or tippled for the further applications.
The main purpose of tippling the coal in to the hoppers is completed with the above
operations of the tippler using advanced technology with cost effective & less
duration of the process are given in table4.1.

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Table 4.1 Operation time

OPERATION
PLACEMENT OF WAGON
WEIGHING
TIPPLING OPERATION
PAUSE
RETURN
WEIGHING
TOTAL

TIME DURATION
59 seconds
3 seconds
39 seconds
5 seconds
35 seconds
3 seconds
144 seconds

Fig.4.2 Ladder diagram for tippling reverse

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CHAPTER 5
CONCLUSIONS
This study is carried at RTTP, Kadapa to understand the operation of wagon
tippler and side arm charger based on PLC. Most of the wagon tipplers contain
electromechanical and electronic gears indicating the control system. Side arm
charger couples to the front of the wagon to draw a single loaded one to proper
position on tippler platform. The wagon tippler operation is done by using PLC which
monitors various parameters of a wagon tippler such as hydraulic motors, drives etc...
By using PLCs faults occurred during the wagon tippler operation can be determined
accurately within a fraction of seconds. But in case of relays it takes some time to find
where the fault has occurred and for fault clearance so it is a time consuming process,
which is eliminated by using the PLC based operations. The total time consumed by
the tippler to tipple the coal in to the hoppers is 75 seconds which is a fast process,
also the installation cost is less when compared to the relays and power consumed is
less. This technology is the advanced version of RELAYS.

25