Industrial Automation(PLC) and Electrical Motor Faults.

Hey my beloved steemians, today was another day to participate in a steemit learning challenge titled Industrial Automation(PLC) and Electrical Motor Faults. The class was indeed impactful, how is to present how well I can do.

Let's have a view of the questions and my answers below..

Task

1:

A. What do you understand by industrial automation?

Answer...

Industrial automation means or can be referred to the use of control systems like computers, robots and information technologies to handle different processes and machinery in any industrial environment this includes manufacturer having task like production, manufacturing, testing and packaging.

Automation is always aims to improve efficiency reduce human intervention, enhance safety and lower production costs by making use of systems that can operate all by itself or a little instruction given, it involve a variety of technologies which include programmable logic controllers (PLCs) as related to our learning challenge, sensors, robotics and artificial intelligence as well.

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Task

2:

B. Write about the importance of industrial automation during the Industrial Revolution.

Answer...

Industrial automation played a very important role during the Industrial Revolution most importantly in transforming manufacturing processes and the economy, When automatiion in the modern sense of the term "using computers and advanced robotics" didn't exist, the period marked the emergence of mechanical systems that automated many tasks previously done by human hands

One of the important innovations during the Industrial Revolution is the development of machinery luke the spinning jenny, power loom and steam engines, those innovations allowed the manufacturers to greatly increase their production capacity and efficiency as well as speed.

Automation reduced the reliance on skilled labours for some particular tasks and improving output and lowering costs used to paid before a task could complete, This shift enabled factories to produce goods on big scale than the way it was before which makes making products more affordable and accessible.

The increased in this productivity lead to the growth in our industries like textiles, iron and coal mining, it also promote urbanization as people moved to cities to work in new factories created. I will say that industrial automation contributed to economic growth because creating new job opportunities and foster the rise of mass production and consumption.

yes!!!, industrial automation during the Industrial revolution laid the groundwork for modern manufacturing and technological advancements whick marks a turning point in how goods were produced and distributed before.

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C. Write the names and operations of various parts of a PLC with a picture.

Task

3:

Answer...

Here I'm going to use my computer motherboard to point out the names and operations and important parts of a PLC (Programmable Logic Controller) that incorporate a computer motherboard and related components, I believe this to be a better illustration

1. The CPU (Central Processing Unit)
   Operation: as we are usually taught in schools, the CPU is the brain of the PLC, it processes inputs from sensors or other devices, executes the control program and therefore generates it outputs. It carries out logic operations, data processing and controls the all the operation of the PLC system.

2. EEPROM (Electrically Erasable Programmable Read-Only Memory):
   Operation: here we refer to storage devices, EEPROM stores the control program and configuration settings as well, Unlike traditional ROM it can be electrically erased and reprogrammed which this allows the PLC program to be updated or modified without removing those memory chip in the board.

3 Input/Output (I/O) Modules**:
Operation: These modules surface the PLC with external devices like sensors, actuators or switches as show in my picture above., the input module reads signals from external devices and the output module sends control signals to actuators let's take for instance in motors lights. I/O modules allow the PLC to interact with it physical environment.

1. Bus Controller:
   Operation: here this bus controller manages communication between different components of the PLC which includes the CPU, memory, I/O modules and other peripheral interface, It controls the data transfer over the internal bus system which ensures that the right data reaches the correct components at the right time.

2. Memory:
   Operation: here memory in a PLC stores data for short time or long time, control programs and operational information, there are different types of memory which are the ROM (Read-Only Memory) for the system hardware and the RAM (Random Access Memory) for temporary data storage and or flash memory for storing the user program and documents. Memory is important for executing the control tasks and maintaining program integrity even when the system is powered off.

Those components I mentioned work together to allow a PLC to control industrial processes efficiently and more reliable.

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Name five input and output electrical and electronics devices operated by PLC.

Task

4:

Answer...

Yes a Programmable Logic Controller (PLC) is used to control industrial processes and machinery through input and output devices, here I will state five common input and output devices operated by a PLC.

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Input Devices

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1. The Push Buttons: It Used for manual operation and then in triggering processes

2. The Proximity Sensors: it is use to detect the presence or absence of objects or materials in a machine

3. The Limit Switches: it is used to detect the position of yhe moving parts or the equipment

4. The Temperature Sensors: it is used to measure temperature levels and then send signals to the PLC

5. The Photoelectric Sensors: it is used to detect objects using light and then provide feedback to the PLC

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Output Devices

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1. Motors: it is used to drive mechanical systems based on PLC control signals

2. The Solenoids: it is use for controlling valves and actuators

3. The Relays: it is used for electrically control circuits and devices by switching it either on or off

4. The Indicator Lights: it is used to provide visual feedback about the any system status

5. The Horns/Alarms: here it give audible signals in case system have faults or emergencies

the above devices I mentioned allow the PLC to interact with and control machinery, automation systems and processes as well.

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E. Practical:
The power load for setting up an industry is assumed to be 10 MW. Five 5 kW and three 45 kW three-phase motors will be used in the production of the product. You are an electrician or electrical engineer in that company. Perform the following electrical works with responsibility:

Task

5:

Answer...

As an electrical engineer responsible for designing and implementing the electrical system for the industry I will perform the following, my exercise below.

Electrical Load Calculation

1. Calculate the total power load for the industry setup, 10,000 kW (10 MW)

2. Calculate the total motor load

   1. Five 5 kW motors, 5*5 kW = 25 kW

   2. Three 45 kW motors, 3 * 45 kW = 135 kW

   3. Total motor load, 25 kW + 135 kW = 160 kW

3. Calculate the total electrical load, 10,000 kW + 160 kW = 10,160 kW

Transformer Selection

1. I determine the required transformer rating based on the total load and power which assume 0.9.

2. I Calculate the transformer rating, 10,160 kW / (1000 x 0.9) = 11.29 MVA

3. I Select a suitable transformer size, 12 MVA

Motor Protection and Control

1. I Calculate the current requirements for each motor

   1. Five 5 kW motors ... I = P / ( √3 x V x PF)= 7.2 A which I assume 400 V, 0.8 PF

   2. Three 45 kW motors, ... I =P / (√3 * V * PF) = 64.4 A which I assumed 400 V, 0.8 PF

2. I Select suitable circuit breakers and motor protection devices.

Power Distribution and Cabling

1. I design the power distribution system including the main distribution amd board subdistribution boards, and cabling

2. I Select suitable cable sizes based on the calculated current requirements and distance.

Power Factor Correction (PFC)

1. I determine the power factor correction requirements based on the total load and power factor

2. I Select suitable PFC equipment to maintain a power factor of 0.9 or higher

Earthing and Safety I conduct

1. I design the earthing system which I include the earthing grid, earthing rods and rhe bonding

2. I ensure compliance with relevant safety standards and regulations

3. I install residual current devices and earth leakage protection devices as required

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The incoming electrical line in the industrial area is 11 KV. Prepare a transformer specification by first calculating the load.

Answer...

Transformer Specifications

Here is a summary of the transformer specifications

• Rating: 15 MVA

• Primary Voltage: 11 kV

• Secondary Voltage: 433 V or other suitable voltage for the industry setup

• Power Factor 0.9

• Frequency 50 Hz

• Cooling Onna oil or other suitable cooling method

• Insulation Class F or other suitable insulation class

these specifications are based on the calculated load and may need to be adjusted based on specific industry requirements and local regulations

Draw the starter (power circuit) for running a 5 kW three-phase motor and write the required materials.

Requirements for a 5 kW Three Phase Motor Starter

1. DOL "direct On Line" Starter

Contactor "3 pole"; use to switch the motor

Overload Relay; use to protect the motor from overload

MCCB/MCB; use for short circuit protection.

Start/Stop Push Buttons; use for manual control

Indicator Light; use to show motor status but it is optional

Auxiliary Contacts; use for interlocking

Wiring and cables; use for the connections

Draw the starter (power circuit) for running a 45 kW three-phase motor and write the necessary materials.

material that is required to run a 45 kW three phase motor you will need the below

Electrical Components

Three-phase motor; 45 kW, suitable for the application.

Circuit breaker; 3 pole which is suitable for the motors full load current

Contactors; 3 pole use for motor control

Overload relay; use for motor protection

Thermal overload relay; use for motor protection

Cable; it is suitable for the motor FLC that is full load current and voltage rating

Wiring and Accessories

Three phase cable

Cable glands; use for cable entry into motor the and control panel

Terminal blocks; use for connections in control panel

Earthing kitt; use for motor earthing

Control panel; use for housing electrical components

Power Supply

Three phase power supply: 380 - 415V

Safety Equipment
Motor protection devices; like thermal sensors and others

Emergency stop button; use for safe shutdown

Safety relays: use for monitoring and the controlling motor operation

A 15 kW motor will keep the product in a fixed location. The motor must run in both directions. Draw the motor's power circuit and write down the materials required for making the circuit.

The materials required

Electrical Components

• 15 kW motor

• 3 pole contactor

• Overload relay

• Forward-reverse control circuit example DOL starter with reversal

• Circuit breaker

Wiring and Accessories

• 3 phase cable

• Cable glands

• Terminal blocks

For Control Devices

• Forward reverse pushbuttons
• The emergency stop button

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Task	6:

F. Review the pictures of the motor checked with a multimeter in my lesson and write your opinion in your own words.

If the result of checking the motor seems good to you, then present your reasoning.

If you think the motor is bad, explain how you know it is bad.

My reviews goes this way based on your readings you provided from the motor check using the multimeter 13, 11, and 30 kilo-ohms the motor is considered to be in poor condition, the expected resistance range for a good motor should be between 0 to 10 ohms.

Values as high as 13, 11, and 30 kilo-ohms indicate and a clearly show high resistance which is suggests that the motor windings can likely damaged or there is a problem with the internal circuitry, this excessive resistance is a clear sign that the motor is not functioning properly and would likely need repair or replacement.

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I won't learn alone so therefore I'll invite my @presh001, @samuelnketa and @suboohi to participate with me.

Thanks you all for your time and support