SLC-S22/W4: Industrial automation (PLC) and electrical motor faults

Assalam-o-Alaikum!

Hello friends! I'm @moazzamushtaq from #pakistan and I warmly welcome all of you to my post. I hope that you all will be fine and will be enjoying your lives. Today I'm going to participate in the SLC-S22/W4's learning course in Steem For Pakistan community. The topic is "Industrial automation (PLC) and electrical motor faults" and teacher of this course is sir @mahadisalim. Let's come to the topic;

[A.] What do you understand by industrial automation?

Industrial automation is a process of using the technology and machinery to control the various processes of industries as well reducing the human interventions. For controlling the processes and to monitor, control and optimize industrial operations, the automation used various sensors, actuators, control systems and software.

ndustrial automation is helpful as:

● It increase efficiency
● Improve the accuracy
● Enhance the productivity
● Reduce costs in industries
● Improve safety by reducing human interventions

Industrial automation uses various technologies like:

● Programmable Logic Controllers (PLCs) mean it is the computer base controlling technology and has a main part in automation.
● Sensors and Actuators are use to detect things in the system.
● Robotics and Machine Learning mean use of AI and robots for reduce human interventions.

In conclusion, industrial automation is an important method for increasing efficiency and productivity with less costs and struggles.

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

The Industrial Revolution which ranged from the late 18th century to the mid 19th century, the industrial automation played a crucial role in increasing the work efficiency as well as reducing the costs and human interventions. And during all this revolution, the industrial automation are used like use of technology and machinary. Industrial Revolution means the instead the use of manual and traditional methods of running things, the new methods has been applied for efficiency working and for increasing productivity.

Industrial Automations is the use of machines and modern technology in industries, the human interventions has been replaced by motors and AI robots. Nowadays machines are doing the work that was previously done by humans. The human interventions, in the modern era, in the industrial processes has been done by sensors and actuators that play a role of communication in decisions making just like humans. Overall, industrial automation is a great change in the industries which is done during industries revolution.

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

A Programmable Logic Controller (PLC) consist of several key parts each key is responsible for specific operation. Below are the names of parts:

1. Central Processing Unit (CPU):

The brain of the PLC is CPU. CPU perform pivot role in the PLC system and it processes input data, give instructions and send output data to control various parts within the system.

2. Input/Output Modules:

Input and Output modules are shown in above picture. Both these modules contact the CPU to outside terminal mean input module receives signals from sensors and output send the signals to actuators like lights.

3. Power Supply:

This part of PLC provide electrical power supply to CPU and other parts of PLC.

4. Processor:

Processor process the data and send and receive signals from I/O modules for controlling purpose.

5. Memory:

Memory store the input and output data and is esential part of PLC for logic control.

6. Programming Device:

This is a device within PLC system which work on the basis of input data and help in modifying data.

7. Communication Module:

This module help to communicate with other PLCs, computer or devices and facilitate in control and monitoring.

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

Below are five inputs and outputs electric and electronic devices operated by Programmable Logic Controller (PLC):

Output Devices

Some output devices of PLC are;

1. Relay Modules: These control the flow of control to other devices like motors, valves etc.

2. Solid-State Relays (SSRs): These also control the flow of electric current to devices such as heaters, lights etc.

3. Contactors: Contactors also control current to some devices like pumps, fans (fans keep the system cool).

4. Valves: Valves are useful for controlling the flow of fluids and gasses within industrial system.

5. Alarm Horns/Lights: They give us awareness from inner faults and warnning from alarming system.

Input Devices

Some input devices of PLC are;

1. Proximity Sensors: These sensors detects the presence or absence of devices within the system by sending message to PLC.
   signals to the PLC.

2. Thermocouples: Use to measure the temperature of the system.

3. Photoelectric Sensors: These type of sensors detect light presence and issues.

4. Mechanical Switches: Switches detect the movement or position of devices of the system.

5. Pressure Sensors: These are very important type of sensors and measure pressure of the system.

[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:

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

For calculation of load, the variablea will be used are:

● Types and number of equipments and their ratings.
● Total perating hours.
● Power factor/load factor.
● Efficiency in ratings.
● Voltage and frequency of load given.

Recomended transformer specification:

After calculation I have get to know that specification for transformer of 11KV electric line will be:

Primary voltage	11 kV
Rating	15 MVA or ~60hz
Secondary voltage:	415 V or 690 V
Frequency	50 Hz
Power factor	0.8

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

material required:

material name	quantity	rating
Magnetic Contactor	1 Pcs	60A
Overload Relay	1 Pcs	35A
MCCB	1 Pcs	90 A
Timer	1 Pcs	~30 Sec

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

material required:

material	quantity	ratings
Magnetic Contactor	1 Pcs	200 A
Stator winding	3 connections
MCCB	1 Pcs	200 A
Rotor	10 poles
Relay	1 Pcs	100A
Timer	1 Pcs	~35 Sec

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.

For making a motor that can run in both directions we need:

● Reversing circuit
● Reversing magnetic contactors
● Interlocking system for preventing simoltaneus current loss.

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

To evaluate whether the results of checking the motor are good or not we look forward to some key points like;

● Efficeincy
●Temperature
● Electrical readings
● Performance
● Physical conditions

All these key points tells us the results good or bad. But here as motor is checking by multimeter mean I have to check its electrical readings in which current, resistance etc included.

Electrical Readings:

I have reviewed the pictures in which sir @mahadisalim is checking the electrical readings by connecting two wires of same colour. I have get to know after reviewing that connection is bad. The electrical readings are:

Red to red wires	13.30 kiloohms
Yellow to yellow	11.77 kiloohms
Blue to blue	30. kiloohms

Note: I said this connection bad after reading the table given in the lesson by teacher.

I have shown a table chart below by which we can understand the good or bad of the motor.

Connection of knob of multimeter with cable Good Meter Value	Bad Meter Value
Red to Red	0-10 Ohms Kiloohms to infinity
Yellow to Yellow	0-10 Ohms Kiloohms to infinity
Blue to Blue	0-10 Ohms Kiloohms to infinity

_{table is taken from lesson}

So this is my answer of part F according to my poor understanding of this part. Hopefully I have given the right answer.

At the end I am inviting @fjjrg, @uzma4882, @suboohi to participate in this course.

Thanks.

With best wishes:
@moazzamushtaq.