senior project report -...

2014

Hussain Abbas

Qassim Ashoor

20090222

David Krause

Senior Project Report

Hussain Ashoor 20090222

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Abstract

The aim of project was to design, build, program and test a separation system

which is used in BANAGAS Company which is operating now to gets gas from

the ground. The designing of this project was done by using Altium designer

program which designed the circuit in it and also the Solid Works was used to

design some hardware parts. The building part of this project was to make a

wood board to fix the tanks which made with acrylic plastic and fix all the

sensors and equipment on it for simulation. The programming part was into

two parts, first part was using PLC program RSlogix 5000 and Mbed

microcontroller which will indicate any pump on the LCD display. Furthermore,

the SCADA program was used to give an advantage of operating the process

by following the process through computer. The process is the main and the

most important process in Banagas Company. This process is extracting raw

oil from the ground which without this process the company will shutdown.

The benefit of this project is to make a simulation for trainees at the Company

to let them become familiar with the company processes. After finishing the

project some points were mentioned for how to improve the project in future

such as using better equipment, components, sensors and modules for the

PLC controller.


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Table of Contents Abstract ..................................................................................................................... 2

Table of Contents ...................................................................................................... 3

Table of Figures ........................................................................................................ 4

Table of Tables ......................................................................................................... 5

Project Objectives ..................................................................................................... 6

Objectives and task description ................................................................................. 7

Altium .................................................................................................................. 12

Relay Circuit ........................................................................................................ 20

Software .............................................................................................................. 28

PLC Program ................................................................................................... 28

PLC modules input and output list .................................................................... 29

Discussion ............................................................................................................... 32

Observations and recommendations ....................................................................... 33

Appendix A .............................................................................................................. 34

PLC program rungs ............................................................................................. 34

Mbed program code ............................................................................................. 41

Appendix B .............................................................................................................. 44

Datasheets .......................................................................................................... 44

Appendix C ............................................................................................................. 47


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Table of Figures Figure 1: Bilge pump 700 GPH .................................................................................. 7

Figure 2: Ultrasonic sensor fixed in the project .......................................................... 7

Figure 3: Level sensor switch .................................................................................... 8

Figure 4: level sensor position is normally open ........................................................ 8

Figure 5: level sensor position is normally close ........................................................ 8

Figure 6: MQ2 gas sensor ......................................................................................... 9

Figure 7: Temperature sensor ................................................................................... 9

Figure 8: Fan 24 volts ............................................................................................. 10

Figure 9: LCD display 16 X 2 .................................................................................. 10

Figure 10: LCD connection pins .............................................................................. 10

Figure 11: seven-segment ....................................................................................... 11

Figure 12: seven-segment voltage divider and pins header ..................................... 12

Figure 13: one the seven-segment display circuits .................................................. 13

Figure 14: Switching regulator circuit LM2576 ......................................................... 14

Figure 15: Voltage comparator circuit ..................................................................... 15

Figure 16: Mbed voltage divider with pins header ................................................... 16

Figure 17: Mbed chip with LCD display ................................................................... 17

Figure 18: PCB circuit ............................................................................................. 18

Figure 19: PCB relay circuit ..................................................................................... 20

Figure 20: Relay schematic circuit .......................................................................... 21

Figure 21: Solid work design of the tank .................................................................. 22

Figure 22: The tank after building ........................................................................... 23

Figure 23: 3D concept which was made in Solid works ........................................... 23

Figure 24: 3D printer machine making the concept.................................................. 24

Figure 25: Stand of ultrasonic sensor dimensions ................................................... 24

Figure 26: Wood board and tanks fix on it ............................................................... 26

Figure 27: Control panel .......................................................................................... 26

Figure 28: Mbed pins ............................................................................................... 30

Figure 29: SCADA main page ................................................................................. 31

Figure 30: Rung 0 to 2 ............................................................................................. 34

Figure 31: Rung 3 to 5 ............................................................................................. 34

Figure 32: Rung 6 to 9 ............................................................................................. 35

Figure 33: Rung 10 to 13 ......................................................................................... 35

Figure 34: Rung 14 to 17 ......................................................................................... 36

Figure 35: Rung 18 to 19 ......................................................................................... 36

Figure 36: Rung 20 to 22 ......................................................................................... 36

Figure 37: Rung 23 to 24 ......................................................................................... 37

Figure 38: Rung 25 to 27 ......................................................................................... 37

Figure 39: Rung 28 to 30 ......................................................................................... 37

Figure 40: Rung 31 to 32 ......................................................................................... 38

Figure 41: Rung 33 to 34 ......................................................................................... 38

Figure 42: Rung 35 to 37 ......................................................................................... 38

Figure 43: Rung 38 to end ....................................................................................... 39

Figure 44: Beginning alarm add on .......................................................................... 39

Figure 45: Beginning alarm add on 2 ....................................................................... 39

Figure 46: Leakage alarm add on ............................................................................ 40


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Figure 47: High temperature add on ........................................................................ 40

Figure 48: Code 1 to 18 ........................................................................................... 41

Figure 49: Code 20 to 45 ......................................................................................... 41

Figure 50: Code 47 to 72 ......................................................................................... 42

Figure 51: Code 74 to 93 ......................................................................................... 42

Figure 52: Code 96 to 110 ....................................................................................... 43

Figure 53: LM2576 datasheet .................................................................................. 44

Figure 54: LM2576 drawing circuit in the datasheet................................................. 45

Figure 55: Ultrasonic sensor wiring colors ............................................................... 46

Figure 56: Ultrasonic teaching way .......................................................................... 46

Figure 57: Panel in process ..................................................................................... 47

Figure 58: Panel in process 2 .................................................................................. 47

Figure 59: Board and fixing the tanks on it with the level sensors ............................ 48

Figure 60: Process in progress and the pump1 & 2 are on ...................................... 48

Figure 61: Process in progress and showing that pump 2 is stopped ...................... 49

Figure 62: Process in progress and filling Bapco tank with oil ................................. 49

Figure 63: PCB circuit ............................................................................................. 50

Figure 64: Relay PCB circuit ................................................................................... 50

Table of Tables Table 1: switching regulator results ......................................................................... 14

Table 2: bill of material ............................................................................................ 19

Table 3: Relay Circuit table of materials .................................................................. 20

Table 4: PLC module output list............................................................................... 29

Table 5: PLC module input list and analog input list ................................................ 29


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Project Objectives

The objectives of this project were:

- Implementing what was learned in the engineering years since year 1

until the 3rd year of studying

- Working individually to produce a level 7 fully functioning project

- Showing that the students are capable of doing the research and

solving the problems that they face during doing a project

- Creating a project from a start by starting first with an idea until

finishing the project by their selves.

- Improving critical thinking and innovation for the students and giving

them the chance of improving their on projects.

- Search about how to build the circuits required for this project.


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Objectives and task description

Bilge Pump

It was used in the tanks to transfer water from the main row tank to the

separation tank and then drive them to the final stage in the process. The

pumps could operate till 12 volts but will be used with 3 volts supply.

Figure 1: Bilge pump 700 GPH

Ultra sonic sensor

The Ultrasonic sensor was used in Bapco store tank to detect and indicate the

level of the oil that will be store in the tank so it could be transfer to Bapco

after it reaches the high level. The sensors have to be taught by using the

teaching button on the top of them, the sensors come with an installation

instruction to provide the technique of teaching them. See appendix B

Figure 2: Ultrasonic sensor fixed in the project


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Level switch (sensor)

The level switch sensor PTFA0100 from CELDUC was used to maintain the

water level in separation tank till it reaches 100 % and to let the bilge pump

turn on and deliver the water to Bapco tank and also to the Boiler tank. The

level switch sensor has a temperature rating from 0-70 C, its maximum

switching current is 0.5 amps and its maximum switching voltage is 200 Volts

DC.

Figure 3: Level sensor switch

Figure 4: level sensor position is normally open

Figure 5: level sensor position is normally close


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Gas & Smoke detector

This MQ2 was mainly used to detect the gas (Smoke) along the process

where it was actually used during the entire process. This sensor is highly

accurate by detecting gas. The circuit voltage is 5 volts and the resistance

could be adjusts because of the variable resistor.

Figure 6: MQ2 gas sensor

Temperature sensor PT100

It was mainly used to measure the temperature of the water at the boiler tank

to keep monitoring the boiling temperature which will give an alarm when the

temperature reaches certain temperature.

Figure 7: Temperature sensor


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Fan 24 Volts

The fan was used as an exhaust system in the project, which is delivering the

smoke from a tank to another for example from separation system tank to

Banagas tank which will be stored there for another process.

Figure 8: Fan 24 volts

LCD 16 X 2

The LCD display was used to keep monitoring the operation step by step and

to detect any leakage could happen during the operation. Moreover, any

pumps operating will be shown on the LCD display.

Figure 9: LCD display 16 X 2

Figure 10: LCD connection pins


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Seven-segment

A seven-segment display (SSD) or seven-segment indicator is form of

electronic display device for displaying decimal numerals that is an alternative

to more complex dot matrix displays. Seven-segment displays are widely

used in digital clocks, electronic meters and other electronic devices for

displaying numerical information. Six 7-segments were used in the project and

they were divided into two. Each three 7-segments were indicating a process.

First three seven-segments were used to indicate the temperature of Boiler

tank. Second three seven-segments were used to indicate the level of oil level

in Bapco store tank.

Figure 11: seven-segment


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Altium

Mbed, Seven-Segment, Voltage regulator and voltage comparator circuit

Figure 12: seven-segment voltage divider and pins header

A header of 10 pins was used to take signals from PLC controller which gives 24V to

the 7segment circuits which need 5V. For that, resistors were added to reduce the

voltage to 5V which is voltage divider circuit. A calculation was used to find the

resistors value.

𝑉𝑜𝑢𝑡 = 𝑅𝑏

𝑅𝑎 + 𝑅𝑏 × 𝑉𝑖𝑛

5𝑉 = 4.7𝐾

𝑅𝑎 + 4.7𝐾 × 24𝑉

𝑅𝑎 = 18𝐾

The 4.7Kohm and 18Kohm were used because they are available in the university

store.


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Figure 13: one the seven-segment display circuits

Seven-segment circuit contains of two main parts the seven-segment displays

and the (CD4511BE) decoder. There are three seven-segment displays in

one part and each seven-segment connected with a decoder. A decoder is a

device which does the reverse operation of an encoder, undoing the encoding

so that the original information can be retrieved. The same method used to

encode is usually just reversed in order to decode. The PLC output will supply

the binary code to the decoders, then the decoder will encoder the binary

code to the seven-segment to display the number. This circuit will be supplied

from the PLC 24V. For the decoders it need about 5V, so the (LM2576) chip

has been used to reduce the voltage from 24V to 5V for the decoders. For the

seven-segment it need about 2V so a 470ohm resistors pack used to reduce

the value from 5V to 2V.


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Figure 14: Switching regulator circuit LM2576

This circuit will be supplied from the PLC 24V and it will reduce the voltage to

5V which is needed in most of the PCB components. So the (LM2576) chip

has been used to reduce the voltage from 24V to 5V. Moreover, the regulator

circuit was designed in the Altium program and after that it was connected on

bread board to do some experiments. The inductor that was used in the circuit

was (221) 200uH which near to value 150uH as shown in the datasheet and

also that inductor could be alive till 2 amps. The table below is showing the

experiment results.

Table 1: switching regulator results

Load Current Temp Voltage Theory current

3.3 ohms (100 watts)

1.36 amps 38 C 4.7 V 1.4 amps

2 X 4.7 ohm (100 watts)

Parallel ( 2.35 ohm)

1.9 amps 52 C

After 30 min 73 C

4.7 V 2 amp

Besides, in the beginning the MC 34063 was tested to be supplier voltage for

the project but it has a maximum of 1.5 amps which can operate but for the

project was done it needs around 2 amps to be operate which the LM 2576 is

suitable to be used instead of MC 34063 which gets heat faster than LM 2576.


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Figure 15: Voltage comparator circuit

Voltage comparator is a device that compares between two voltages or even

currents and shows which is larger. The voltage comparator circuit was added

in the circuit to sense the smoke leakage happened through the process.

Furthermore, the circuit gives both of PLC and Mbed a signal that there is a

leakage in the plant which will stop the process immediately and switch on the

siren. The comparator circuit gets 5 volts from the switching regulator circuit.

The Op amp 358 was used to generate the signal to the PLC and give the

signal to switch on the Alarm. A trimmer 10k was used to change the analog

signal to digital so it gives the signal to PLC.


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Figure 16: Mbed voltage divider with pins header

A header of 10 pins was used to take signals from PLC controller which gives 24V to

the Mbed pins which need 3.3V. For that, resistors were added to reduce the voltage

to 3.3V which is voltage divider circuit. A calculation was used to find the resistors

value.

𝑉𝑜𝑢𝑡 = 𝑅𝑏

𝑅𝑎 + 𝑅𝑏 × 𝑉𝑖𝑛

5𝑉 = 4.7𝐾

𝑅𝑎 + 4.7𝐾 × 3.3𝑉

𝑅𝑎 = 30𝐾

The 4.7Kohm and 30Kohm were used because they are available in the university

store.


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Figure 17: Mbed chip with LCD display

Mbed is a microcontroller which based with 40 pins and it was designed to

give a highly productive solution for product development which connects with

internet. The Mbed was used in the project to show a process that happens

on the LCD display. The LCD display it is a liquid crystal display and it is used

in wide range of application such as computer mentoring, television and as

used in this project monitoring the process. As showing above in figure (16)

the LCD was connected with Mbed from pin 15 to 20 which will display the

process.

The PCB design is below in figure (17) which contains all the above circuits in

one PCB which will be high level of PCB design.

The client has request to put the inputs headers on the top of the PCB and the

output which are the seven segment holders on the bottom. Moreover, the

Mbed chip was put on the left as shown in figure (17).


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Figure 18: PCB circuit


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Comment Designator Footprint LibRef Quantity

LM2576 *LM1 LM2576 LM2576 1

Op Amp AR1 Opm Amp Op Amp 1

Cap C1, C2 CAP RAD 8D 9H 3.5P

Cap 2

Diode Schottky

D1 DO-35 DIODE AXIAL

Diode Schottky 1

Inductor L2 inductor Inductor 1

MBED M1 MBED CON 40 MBED 1

LCD - TEXT M2 LCD display LCD - TEXT 1

Header 5X2H P1, P2, P3, P5, P6, P7 header10s Header 5X2H 6

Header 10 P4, P8 7seg to plc header10

Header 10 2

Header 10_1 P9 header10s Header 10_1 1

3 Pin P10 Gas detector pins Header 3 1

NPN Q1, Q2 trans NPN 2

Res2 R1, R2, R6, R7, R8, R9, R10, R11 , R12, R13, R14, R15, R16, R17, R18, R19, R20, R21, R22, R23, R24, R25, R26, R27, R28, R32, R33, R34, R35, R36, R37, R38, R39, R40, R41, R42, R43, R44, R45, R46, R47, R48, R49, R50, R51, R52, R55, R56, R57, R58, R59, R60, R61, R62, R63, R64, R66, R67, R68, R69, R71, R72, R73, R74, R75, R76, R80

RES AXIAL 6X2.3 P10.16

Res2 67

Res Pack4 R3, R4, R5, R29, R30, R31

DIP-16 Res Pack4 6

Res2 R53, R54, R65, R70, R78

AXIAL-0.4 Res2 5

Res2 R77, R79 RES AXIAL 3.5X1.7 P5.08

Res2 2

CD4511BCN U1, U2, U3, U4, U5, U6

CD4511 CD4511BCN 6

Table 2: bill of material


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Relay Circuit

A relay is an electrically operated switch. The relay circuit was designed on a

saperate PCB for a higly purposes. Furthermore, the method of using relays

wes to switch on the pumps with a certain voltage. The relay opens depends

on a voltage that was given by the power supply which is in parellel with the

PLC controller and also on the other channel fixed on a voltage to give the

relay the pulse to switch on the pumps.

Figure 19: PCB relay circuit

As showing below the schematic circuit was designed a boxes but the foot

print was designed one according the relay physical dimension. Furthermore,

the pumps were used a connector of two pins and the pin hole was expended.

Table 3: Relay Circuit table of materials

Comment Description Designator Footprint Lib Ref Quantity

Header 3X2 Header, 3-

Pin, Dual row P1 header6relay Header 3X2 1

Power Supply

PowerSupply1 CON Euro 5mm

2 Pin LP Power Supply

1

Pump

Pump1,Pump2, Pump3, Pump4

CON 2PIN FCI 200220110-H02

Pump 4

Relay

Relay1, Relay2, Relay3, Relay4

Relay Relay 4


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Figure 20: Relay schematic circuit


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Solid Works

Solid Works program was used to draw and design a piece of equipment that

was considered to build in the project as a conical pipe to deliver the smoke

from a fan to another fan. In fact, the designed piece was carried out

Bernoulli’s principles where it has two different cross sectional areas. This will

make a different in pressure and velocities of the smoke as it will be

discussed in the research part. Furthermore, other design also was

considered to be design which was a boiler tank which was asked for a

dimension of the tank and it was drawn in Solid Works also. Moreover, the

ultrasonic sensor should have a stand which was also designed in Solid

Works and the stand should have a height more than 28 cm so the ultrasonic

sensor can sense the water. The below figures are the designed concepts

and also after it was built.

Figure 21: Solid work design of the tank


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Figure 22: The tank after building

Figure 23: 3D concept which was made in Solid works


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Figure 24: 3D printer machine making the concept

Figure 25: Stand of ultrasonic sensor dimensions


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Fabrication

Acrylic & Wood Board

Acrylic sheets are fairly strong, light weight, easily molded plastics, mainly

used for clear or tinted glazing and colored sanitary fittings. Acrylic sheets

melt and burn easily, so that is a fire hazard as well as having low fire

resistance, although it can be broken to allow escape and unlike glass does

not splinter into sharp pieces. Wood board is a place that the project fitted on

to be demonstrated and also it has legs to make it stronger so it can carry the

tanks on itself.

Design

Any project need to be built physically need a base to be put on. The problem

was between choosing acrylic plastic for the board or wood and as know

wood boards have a strong shape which can handle more than 30Kg, but on

the hand the plastic box and the acrylic board can't handle that much of

weight. But the panel side was used with acrylic plastic.0020

Building

As showing in figure (24) the board was built with a measurement that the

boxes will be fit on it. As showing the tanks were built with acrylic plastic 4mm.

Also in figure (25) the panel was built with the same acrylic size 4mm and was

drilled to fix the component in it.


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Figure 26: Wood board and tanks fix on it

Figure 27: Control panel


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Steel

Steel sheets are an alloy of iron which can be used for hard purposes. It can

be fit for boiling process which is can handle the heat. It a conductor metal

which should has an insulator from wood.

Design

It was designed in Solid works program as shown in figure (22) which should

be drawn over there with a physically size which will be printed on a paper

with the dimensions that was drawn with.

Building

The design was handled to mechanical department and it was built in their

labs. As shown in figure (21) the steel tank was done and the insulator was

covered around it so it will be safe when the demonstration is in progress.

LED’s, Buzzer, LCD and seven-segment

LED is a semiconductor diode that converts applied voltage to light and it was

used in lamps and digital displays. Seven-segment indicator is form of

electronic display device for displaying decimal numerals that is an alternative

to more complex dot matrix displays. Seven-segment displays are widely

used in digital clocks, electronic meters and other electronic devices for

displaying numerical information. LCD display it is a liquid crystal display and

it is used in wide range of application such as computer mentoring, television

and as used in this project monitoring the process.

Design

The LEDs were the main components in the panel because it is indication all

the process from the beginning till the end. For that the LEDs that were used

in the panel was 24V which they do not need a resistor as a 2V LEDs.

Furthermore, the panel was designed for them as the dimension of each

component.

Building

The connections were made and each LED negative pin will connect to a

ground which all LEDs will be common grounded and the positive pin will be

connecting to PLC terminal block.


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Software

PLC Program

The process will start by pressing the (Start_button) switch and it will be shut

down for maintenance by pressing the (stop_button) switch three times. The

stop_button was changed to three times in case if the operator pressed the

stop_button by mistake it won’t stop the process and lose the time and should

maintain the process all from the beginning. In the main program after the

Start_button is pressed it will delay the process for 2 minutes in that time the

beginning alarm will turn on for 10 seconds to inform the technician the

process will start after 10 seconds. After that, it will start turning on pump1,

pump2 and the fans. After the level switch reached 100% of the separation

system tank a delay was added also the prepare pump3 and pump4 for

turning on. In other case, when the 100% level switch is closed which become

on it will wait in any case so it won’t let pump3 starts before 4 and the

opposite they will both turn on in the same time after the timer 4 and 5 are

done. In that case the fans will be on all through the process till the

stop_button is pressed three times to shutdown the system. Furthermore, the

pumps in separation system tank will operate to deliver the separated material

which divides into three, (Unwanted) water, Oil (Bapco) and gas which should

be delivered to Banagas. Next, pump 3 and pump 4 will operate to the

mentioned tanks and each tank has a sensor to work on. For example, Bapco

tank has the ultrasonic sensor which will sense the oil level and if it reached

90% it will directly switch off the pump and it will be ready to deliver to Bapco

Company. As the Boiler tank will be receive the water from the separation

tank till the level switch of the separation tank reaches 50% and it will stop

because of the Boiler tank size does not accept more than that to boil. But in

the Boiler tank a temperature sensor is fixed which will sense the water

temperature and will be indicated on the control panel (seven-segment) and

also if the temperature exceeded 120o C will turn on the siren and the alarm

light. A multiplexing out code was added into the program to show the values

on the seven-segment display. The multiplexing code was done for the

temperature and the oil level in the Bapco tank. Besides that, Banagas store

tank will receive the gas from the separation system tank and when the whole


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process is done it will only stop_button to be press so it will shut down the first

cycle of the process till it is ready for the next one. See Appendix A for rungs

explanation.

PLC modules input and output list

Output 1 Local 4 Output 2 Local 6 Run Local:4:O.Data.0 BCD A (Level-

Temp) Local:6:O.Data.0

Stopped Local:4:O.Data.1 BCD B (Level-Temp)

Local:6:O.Data.1

Alarm_Light Local:4:O.Data.2 BCD C (Level-Temp)

Local:6:O.Data.2

Pump_1 Local:4:O.Data.3 BCD D (Level-Temp)

Local:6:O.Data.3

Pump_1_Green Local:4:O.Data.4 Stobre_1 Local:6:O.Data.4

Pump_1_Red Local:4:O.Data.5 Stobre_2 Local:6:O.Data.5

Pump_2 Local:4:O.Data.6 Stobre_3 Local:6:O.Data.6

Pump_2_Green Local:4:O.Data.7 Stobre_4 Local:6:O.Data.7

Pump_2_Red Local:4:O.Data.8 Stobre_5 Local:6:O.Data.8

Pump_3 Local:4:O.Data.9 Stobre_6 Local:6:O.Data.9

Pump_3_Green Local:4:O.Data.10 BL_Level Local:6:O.Data.10

Pump_3_Red Local:4:O.Data.11 BL_Temp Local:6:O.Data.11

Pump_4 Local:4:O.Data.12 Local:6:O.Data.12

Pump_4_Green Local:4:O.Data.13 Local:6:O.Data.13

Pump_4_Red Local:4:O.Data.14 Siren Local:6:O.Data.14

Fans Local:4:O.Data.15 Local:6:O.Data.15 Table 4: PLC module output list

Table 5: PLC module input list and analog input list

Input Local 5 Analog Input Start_button Local:5:I.Data.0 Level Local:2:I.Ch0Data

Stop_button Local:5:I.Data.1 Water_temp Local:2:I.Ch2Data

Reset_Alarm Local:5:I.Data.2

Maintanance_P1 Local:5:I.Data.3




Maintanance_Reset Local:5:I.Data.7

Gas_Sensor Local:5:I.Data.8

Oil_25per Local:5:I.Data.9



Water_25per Local:5:I.Data.12



Local:5:I.Data.15


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Mbed program

Mbed program code is companion program which will show in the LCD

display screen the pumps if they are ON or not. Furthermore, the Mbed

controller was connected on the PCB and then to the PLC with 24V which a

voltage divider was placed to give the Mbed 3.3V so it can get the signal from

the PLC if the pump are on or not. The technique that was used in Mbed code

was pin detect because the process starts with a push button and the only

code could understand that is the pin detect. The library of the pin detect was

added in the Mbed code so it could be recognized. The main condition was

that if a function is happening in that time will directly show it on the LCD

display screen and when it released the written sentence will disappear.

Figure 28: Mbed pins


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SCADA

The Factory Talk View program was used as a monitoring program, which will

show all the processes from the PLC in the plant step by step. The Main page

as showing below has 6 light indications for the water and oil leveling to show

if the tank is full or not. Also, there are 8 indicator lights to show if the pumps

are operating or not. Moreover, the page is showing the status of the process

is running or stopped and the alarm indication (Siren and light) will turn on to

show that there is something in the process happens. The input switches

were changed to internal coil because the SCADA does not recognize the

physical input.

Figure 29: SCADA main page


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Discussion

Each part in the project there were more than one results to choose between.

The chosen results were chosen to be the most suitable values and have

more than one reason to be the chosen. For the voltage divider for the seven-

segment circuit there was more than one value to be chosen from the give the

same output voltage. In this case the values were chosen are 18Kohm and

4.7Kohm,

𝑉𝑜𝑢𝑡 =𝑅𝑏

𝑅𝑎 + 𝑅𝑏× 𝑉𝑖𝑛 .

Using the voltage divider formula the output voltage will be

(𝑉𝑜𝑢𝑡 = 4700

4700 +18000× 24 = 5.0𝑉).

As known the large resistor has a lower wasted current for example in this

case it will be around 1m amps and if a small resistor was used will have a big

waster current which will affect the battery life. From this another point that

needs to be considered is the power rating of the resistors. This goes in favor

of resistors with larger resistance because resistors with lower resistance will

dissipate more power and heat up more as what happened for the transistor

resistor which is connected to the collector pin the one was used in the

beginning was 510 ohm which gets 24V and it burned because of the huge

current gets through it but after changing to 3.3k ohm with 5 watt it does not

gets damage because of the high resistance in the resistor. That means that

they will need to be larger (and usually more expensive and not available

everywhere) than resistors with larger resistance.


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Observations and recommendations

The objectives of this project were achieved by searching to know about the

needed sensors and all the equipments that will be use in this project. All the

components connected by the schematic circuit in the Altium design program.

The circuits were designed to be printed as a PCB. The components were

soldered on the PCB and tested. Fully commented PLC program was written

to control the process and also fully commented Mbed code. Some of the

problems were overcome after analyzing and discovering what was going

wrong. The aims were achieved and also there are several ways to improve

this project:

Using better power supply that can handle more than 5 amps.

Using better PLC modules that can produce more that 205m amps, so

the components will be connected directly to it.

Adding extra reliable sensors all through the process.

If a budget was mentioned for the project it can build the project again

and improve it with better equipment and high sensitive one.


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Appendix A

PLC program rungs

Figure 30: Rung 0 to 2



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Figure 43: Rung 38 to end

Figure 44: Beginning alarm add on

Figure 45: Beginning alarm add on 2


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Figure 46: Leakage alarm add on

Figure 47: High temperature add on


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Mbed program code

Figure 48: Code 1 to 18

Defining all the pumps pin so it can call them back later when the program run.



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This callback will often be of little use as it’s called after every assertion or

desertion. You can define how many continuous samples must be asserted

before the attach_asserted () function is called.


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Appendix B

Datasheets

Figure 53: LM2576 datasheet


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Figure 54: LM2576 drawing circuit in the datasheet

The above circuit was choosing from the LM 2576 datasheet because of the

output current capability which is 3 amps. This circuit is an adjustable circuit

which can be changed by changing the resistors value (voltage divider).


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Figure 55: Ultrasonic sensor wiring colors

Figure 56: Ultrasonic teaching way

From the above figure the teaching method of the ultrasonic sensor is by

pressing and holding the button until the light blinks 3 time and then release it.

The tank should empty and then hold the same button to blinks 4 times then

release it. After that, fill the tank with water full and hold the button to blinks 5

times then release it by then it will be taught with empty and full tank. Finally

to get out from the teaching mode the button should be pressed and hold to

blinks 3 times also then release by then it will be ready to use.


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Appendix C

Figure 57: Panel in process

Figure 58: Panel in process 2


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Figure 59: Board and fixing the tanks on it with the level sensors

Figure 60: Process in progress and the pump1 & 2 are on


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Figure 61: Process in progress and showing that pump 2 is stopped

Figure 62: Process in progress and filling Bapco tank with oil


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Figure 63: PCB circuit

Figure 64: Relay PCB circuit

senior project report -...

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