CHAPTER-1

B.H.E.L AN OVERVIEW

1.1) OVERVIEW
The “Maharatnas” declared by Indian Ministry of Heavy Industries are NTPC,
VSNL, ONGC, IOCL, HPCL, SAIL, BHEL, IPCL, BPCL, etc. Therefore, B.H.E.L.
is one of the Maharatnas and is the largest engineering enterprise of its kind in India
with an excellent track record of performance. The company is engaged in
engineering development and manufacturing of a wide variety of mechanical
and electrical equipment for generation, Transmission and electricity. The
company today enjoys National and International presence featuring in the “Fortunes
Internationals 500” and is ranked among the top 12 companies in the world.

B.H.E.L. has 14 manufacturing divisions, nine service centres and

four power sectors regional centres and about 180 projects sites enables the
company to its customers and provide them with suitable products, systems and
service at competitive prices. Having attained “ISO 9000” certification,
B.H.E.L. is now embarking upon the total quality management.

1
 1.2) BACKGROUND OF THE B.H.E.L

Heavy Electrical (India) ltd. [HE (I) L] was set up in Bhopal in 1956 with a view to
reach self-sufficiency in power equipment‟s vital for industrialization of the country,
then B.H.E.L. came into existence in 1964. Three plants were stabilized under
B.H.E.L. are as follows:
High Pressure Boiler Point- Tiruchy (T.N.)(May 1965)
Heavy Power Plant-Hyderabad(A.P)(Dec 1967)
Heavy Electrical Equipment Plant –Haridwar (U.K.)( May 1967)

As there was need for development of power equipment manufacturing in India

and also with a view to optimally utilize the resources HE (I) L. was merged in
B.H.E.L.

2
 1.3) PRESENT POSITION OF B.H.E.L.

At present B.H.E.L. have 14 manufacturing units. The major units are B.H.E.L. –
Bhopal, B.H.E.L. – Hyderabad, B.H.E.L. –Tiruchy, and B.H.E.L. – Hardwar.
The corporate office is situated in New –Delhi and provides necessary top
management leadership, direction, strategic-planning and operational and
management support Services. It also coordinates the activities, function of various
manufacturing, service divisions and numerous other functional and product groups.
It also looks after the long – term planning in regards to resource and
marketing and also planning for marshalling of human, physical and financial
resources

3
 CHAPTER-2
B.H.E.L. UNIT
TABLE- 2.1) BHEL UNIT

FACTORIES PLACE

1. Heavy electrical equipment plant BHOPAL

2. Control equipment division BANGLORE

3. Heavy electrical equipment plant HARIDWAR

4. Industrial valves plant GOINDWAL

5. High tension ceramic JAGDISHPUR

Insulation plan

6. Transformer plant JHANSI

7. Heavy power equipment plant HYDERABAD

8. High pressure boiler plant TIRUCHIRAPALLI

4
 2.2) COMPANY OBJECTIVES

BUSINESS
MISSION To maintain a leading position as suppliers of quality equipment,
system

and services in the field of conversion, transmission utilization and conversation of

energy for application in the areas of electric power transportation, oil and gas
exploitation industries utilize company‟s capabilities and resources to expand
business into allied areas and other sectors of the economy like defiance,
communication and electronics.

GROWTH :

To ensure a steady growth by enhancing the competitive edge of B.H.E.L. in

existingbusiness in new areas and international operators.

PEOPLE ORIENTATION:

To enable each employee to achieve his potential, improve is potential, improve his
capabilities perceive his role and responsibilities and success of the company. To
invest in human resources continuously and be alive to their needs.

TECHNOLOGY :
To achieve technological excellence in operations by development of
indigenous technology and efficient absorption and adoption of imported
technologies to suit business needs and priorities and provide a competitive
advantage to the company.

IMAGE :
To fulfill the expectation which stakeholders like government as owner, employees,
customers and the country at large house from B.H.E.L

5
TABLE 2.3-MANUFACTURING UNIT AND PROFILE
UNIT

6
7
8
 CHAPTER-3
TECHNICAL COLLABORATORS
TABLE-3.1) COLLABRATORS

9
10
 CHAPTER-4
B.H.E.L. (HARIDWAR): A PROFILE

4.1-PROFILE-
B.H.E.L. Haridwar, one of the keys manufacturing units of B.H.E.L. is located
between Shivalik Mountains and Holy River GANGA. Its manufacturing plant
includes two factories at Hardwar.

On the northern side is heavy electrical equipment plant (H.E.E.P.), which

commenced production in 1967 with know–how from M/S Kraft-work union, AG of
Germany. Now H.E.E.P. has a technical collaboration with M/S Siemens‟
Germany. For manufacturing of large size gas turbine.

Located immediately to the south of H.E.E.P. is the central foundry forge

plant (C.F.F.P.) which was primarily set up for manufacture of alloy steel
casting and forging required for industry and power generation equipment. It
was established in technical collaboration with M/S Crensot – Loire of France.

11
 4.2) PROFILE OF HEEP
ESTABLISHMENT AND DEVELOPMENT STAGES:

 DRP prepared in 1963 – 64 , construction started from Oct 1963.

 Initial product of electric motors started from Jan 1967.

 Major contribution /election /commissioning completed by 1971 –72 as per

original DRP scope.

 Establishing in 1960‟s under the Indo- soviet agreement of 1959 and 1960 in
the area of scientific, technical and industrial co-operation.

 Motor manufacturing technology up dated within siemen‟s

collaboration during 1984 –87 .

 Facilities being modernized continually through Replacement,

reconditing, retrofitting, technological, operational balancing

12
 4.3)HEEP PRODUCT PROFILE

1. THERMAL SETS:

Steam turbines and generator up to 500MW capacity for utility and combined
cycle applications;
capability to manufacture up to 1000MW unit cycle.

2. GAS TURBINES:
Gas turbines for industry and utility application; range-3 to 200 MW (ISO).

Gas turbines based co-generation and combined cycle system.

3. HYDRO – SETS :
Custom– built conventional hydro turbine of kaplan, Francis and
Pelton with matching generators upto 250 MW unit size.

Pump turbines with matching motor-generators

Mini / micro hydro sets.

Spherical butterfly and rotary valves and auxiliaries for hydro station .

4. EQUIPMENT FOR NUCLEAR POWER PLANTS:

Turbines and generators upto 500MW unit size.

Steam generator upto 500MW unit size.

Reheaters / separators .

Heat exchangers and pressure vessels.

5. CASTING AND FORGINGS:

Sophisticated heavy casting and forging of creep resistant alloy steels, stainless
steel and other grades of alloy meeting stringent international specifications.

6. DEFENCE PROCEDURE:
Naval guns with collaboration of Italy.

13
 CHAPTER-5
BRIEF DESCRIPTION OF
MANUFACTURING BLOCKS

5.1) BLOCK-I
Block-I, also known as Electrical Machines Block, is designed to manufacture Hydro
generators, Turbo generators and Testing facilities for Turbo generators. There is also
a special Test Bed for testing of turbo generators of capacity of 500 MW and above.
Apart from facilities and equipment for manufacture of turbo generators, the Block
also has a “Bebitting Section”.Bebitting of bearing liners for Turbo generators,
Turbines, Hydro generators, is carried out in this section. The Block has its
own over speed balancing installation; where the dynamic balancing of Turbo
generator-rotors of less than 500 MW rating is done. Rotors having higher rating are
balanced in OSBT of Block-III.

Fabricated components are received from fabrication blocks (Block-II, IV, VI,
VIII), while other castings, forgings are received from CFFP and other sources for
Turbo generators, Hydro generators and Electrical motors. Stampings are received
from Stampings manufacture section; Block-VI and coils, bars, insulating details
and sheet metal components are received from Block-IV. These are then machined,
assembled, tested and dispatched.

Figure 5.1.a)- Rotor winding

14
Figure5.1.b)Generator Testing

5.2)BLOCK-II
Block-II, also known as Fabrication Block, is a feeder block for various products-
Steam Turbines, Hydro Turbines, Turbo generators, Hydro generators, Electrical
Machines, Apparatus and Control Gear, Aircraft and SRGM (Smooth Recoil Gun
Mounting). The main processes in this Block are cutting, bending and welding
of metal sheets etc. to form fabricated structures.

The Block also has useful equipments like Hydraulic Bending Presses and
Straightening Rollers. Other notable facilities include a CNC six-spindle drilling
machine, a plasma-flame cutting machine, shot-blasting apparatus and various
furnaces. The Block also has facilities for NDT (Non Destructive Testing) of
various components. The following Non-Destructive tests can be conducted – DP
Test (Die Penetration Test), MPI (Magnetic Particle Inspection), UT (Ultrasonic
Testing) and Radiography which includes X-ray and -ray testing.

15
5.3) Block–III
It Known as the TURBINE BLOCK, this is the major block for manufacturing
turbines. All types of Hydro, Steam, Gas and

Nuclear Turbines are manufactured and dispatched from this block. Blades of
different stages are also manufactured here in this block.

5.4) Block- IV
Block-IV, also called as CIM&ACM (Coil and Insulation Manufacturing &
Apparatus and Control Gear Manufacturing), is a feeder block to Block-I. It is
a feeder block for Class „F‟ windings for Turbo generators, Hydro generators
and Class „F‟ and „H‟ insulation for AC and DC motors. It also supplies all
insulation components for Turbo generators, Hydro generators, and motors.
Control panels for Turbo generators, Hydro generators, Industrial drives for
motors, and Turbo generators auxiliaries, contactor relays and master controllers are
also manufactured in this Block.

Figure 5.4.a-Block 4

16
5.5)Block -V

Block-V, also called as Fabrication and Forge Block is again a feeder

block. Fabrication work being done in this block is of Steam Turbine parts like
Condenser, Water Box (Front and Rear), assemblies of LP cylinder, Storage Tanks
etc.; Hydro Turbine parts, Hydro generator and motor assemblies and components.
Forging of carbon, alloy and stainless steels are manufactured in this block. It is
equipped with pneumatic hammers, gas-fired furnaces and hydraulic manipulators.

5.6)Block -VI
Block-VI, also called as Fabrication Block, is also a feeder block.
Manufacturing of all types of dies, including stamping dies and press forms is
carried out in one bay, while stamping for Turbo generators, Hydro generators
and motors are manufactured in other bay. The Block is equipped with Welding,
Drilling, Shot Blasting and CNC Flame cutting facilities. The tems manufactured in
this block are Condensers, Steam Turbine components (Oil Tanks and Hollow
Guide Blades), Hydro Turbine components (Stay Rings), Hydro generator and
motors (Stator Frames) etc.

5.7) Block -VII

Block-VII, also called as Woodworking section, is also a feeder block. Bay-I,
known as Packaging section manufactures packages for packaging and dispatch of
various products.

5.8) Block- VIII

Block-VIII, also called as Heat Exchanger Block, is designed to manufacture Heat
Exchanger Units for Steam Turbines, Hydro Turbines, Turbo generators, Hydro
generators etc. Blanks cut to size and shape are received from Block-II and Block-VI.
These are assembled, welded and machined. The items manufactured here are – LP
Heater, Ejectors, Gland Steam Coolers, Oil Coolers, Oil Tanks, Bearing Covers,
Turbine shaft Covers, Oil Bath and Thrust Bearings

17
 5.1) BLOCK-I

Block-I, also known as Electrical Machines Block, is designed to manufacture

Hydro generators, Turbo generators and Testing facilities for Turbo generators.
There is also a special Test Bed for testing of turbo generators of capacity of 500
MW and above. Apart from facilities and equipment for manufacture of turbo
generators, the Block also has a “Bebitting Section”. Bebitting of bearing
liners for Turbo generators, Turbines, Hydro generators, is carried out in this
section. The Block has its own over speed balancing installation; where the
dynamic balancing of Turbo generator-rotors of less than 500 MW rating is done.
Rotors having higher rating are balanced in OSBT of Block-III.

Fabricated components are received from fabrication blocks (Block-II, IV,

VI, VIII), while other castings, forgings are receivedfrom CFFP and other
sources for Turbo generators, Hydro generators and Electrical motors.
Stampings are received from Stampings manufacture section; Block-VI and coils,
bars, insulating details and sheet metal components are received from Block-
IV. These are then machined, assembled, tested and dispatched.

18
 CHAPTER-6
INTRODUCTION

Development of computerized numerical controlled (CNC) machines is an outstanding

contribution to the manufacturing industries. It has made possible the automation of
the machining process with flexibility to handle small to medium batch of quantities in
part production.

Initially, the CNC technology was applied on basic metal cutting machine like lathes,
milling machines, etc. Later, to increase the flexibility of the machines in handling a
variety of components and to finish them in a single setup on the same machine,
CNC machines capable of performing multiple operations were developed. To
start with, this concept was applied to develop a CNC machining centre for
machining prismatic components combining operations like milling, drilling, boring
and taping. Further, the concept of multi-operations was also extended for machining
cylindrical components, which led to the development of turning centers.

6.1) ADVANTAGES OF CNC MACHINES

 Higher flexibility
 Increased productivity
 Consistent quality
 Reduced scrap rate
 Reliable operation
 Reduced non productive time
 Reduced manpower
 Shorter cycle time
 High accuracy
 Reduced lead time
 Just in time (JIT) manufacture
 Automatic material handling
 Lesser floor space
 Increased operation safety
 Machining of advanced material.

19
 CHAPTER-7
CNC SYSTEMS

INTRODUCTION

Numerical control (NC) is a method employed for controlling the motions of a

machine tool slide and its auxiliary functions with input in the form of
numerical data. A computer numerical control (CNC) is a microprocessor-
based system to store and process the data for the control of slide motions
and auxiliary functions of the machine tools. The CNC system is the heart and brain
of a CNC machine which enables the operation of various machine members such as
slides, spindles, etc. as per the sequence programmed into it, depending on the
machining operations.

The main advantage of a CNC system lies in the fact that the skills of the operator
hitherto required in the operation of a conventional machine is removed and the part
production is made automatic.

The CNC systems are constructed with a NC unit integrated with a

programmable logic controller (PLC) and some times with an additional external
PLC (non-integrated). The NC controls the spindle movement and the speeds and
feeds in machining. It calculates the traversing path of the axes as defined by the
inputs. The PLC controls the peripheral actuating elements of the machine
such as solenoids, relay coils, etc. Working together, the NC and PLC enable the
machine tool to operate automatically. Positioning and part accuracy depend on
the CNC system's computer control algorithms, the system resolution and the
basic mechanical machine accuracy. Control algorithm may cause errors while
computing, which will reflect during contouring, but they are very negligible.
Though this does not cause point to point positioning error, but when mechanical
machine inaccuracies are present, it will result in poorer part accuracy.

This chapter gives an overview of the configuration of the CNC system,

interfacing and introduction to

20
7.1)CONFIGURATION OF THE CNC SYSTEM

Fig.7.1.a shows a schematic diagram of the working principle of a NC axis of a CNC

machine and the interface of a CNC control.

Fig.7.1.a Schematic diagram of a CNC machine tool

A CNC system basically consists of the following:

 Central processing unit (CPU)

 Servo-control unit
 Operator control panel
 Machine control panel
 Other peripheral device
 Programmable logic controller (PLC)

Fig.7.1.b gives the typical numerical control configuration of Hinumerik 3100

CNC system

21
CENTRAL PROCESSING UNIT
The CPU is the heart and brain of a CNC system. It accepts the information stored in
the memory as part program. This data is decoded and transformed into specific
position control and velocity control signals. It also oversees the movement of the
control axis or spindle whenever this does not match the programmed values, a
corrective action is taken.
All the compensations required for machine accuracy (like lead screw pitch error,
tool wear out, backlash, etc.) are calculated by the CPU depending upon the
corresponding inputs made available to the system. The same will be taken care of
during the generation of control signals for the axis movement. Also, some safety
checks are built into the system through this unit and the CPU unit will
provide continuous necessary corrective actions. Whenever the situation goes
beyond control of the CPU, it takes the final action of shutting down the
system in turn the machine.
Speed Control Unit
This unit acts in unison with the CPU for the movement of the machine axes. The
CPU sends the control signals generated for the movement of the axis to the servo
control unit and the servo control unit convert these signals into the suitable digital or
analog signal to be fed to the machine tool axis movement. This also checks whether
machine tool axis movement is at the same speed as directed by the CPU. In case any
safety conditions related to the axis are overruled during movement or otherwise they
are reported to the CPU for corrective action.
Servo-Control Unit
The decoded position and velocity control signals, generated by the CPU for the axis
movement forms the input to the servo-control unit. This unit in turn generates
suitable signals as command values. The servo- drive unit converts the command
values, which are interfaced with the axis and the spindle motors (Fig.7.1.a).

The servo-control unit receives the position feedback signals for actual movement of
the machine tool axes from the feedback devices (like linear scales, rotary
encoders, resolves, etc.). The velocity feedback is generally obtained through
tacho generators. The feedback signals are passed on to the CPU for further

22
processing. Thus the servo-control unit performs the data communication between
the machine tool and the CPU.
As explained earlier, the actual movements of the slides on the machine tool is
achieved through servo drives. The amount of movement and the rate of movement
are controlled by the CNC system depending upon the type of feedback system used,
i.e. closed-loop or open-loop system (Fig7.1.b)
Closed-loop System
The closed-loop system is characterized by the presence of feedback. In this system,
the CNC system send out commands for movement and the result is continuously
monitored by the system through various feedback devices. There are generally
two types of feedback to a CNC system -- position feedback and velocity
feedback.

Fig.7.1(b)Typical numerical control configuration of Hinumerik 3100 CNC system

23
Position Feedback
A closed-loop system, regardless of the type of feedback device, will constantly try to
achieve and maintain a given position by self-correcting. As the slide of the machine
tool moves, its movement is fed back to the CNC system for determining the position
of the slide to decide how much is yet to be traveled and also to decide whether the
movement is as per the commanded rate. If the actual rate is not as per the required
rate, the system tries to correct it. In case this is not possible, the system declares fault
and initiates action for disabling the drives and if necessary, switches off the machine.

Open-loop positioning control

Close-loop positioning control

Fig.7.1.c Open-and Closed-loop positioning system.

24
Velocity feedback
In case no time constraint is put on the system to reach the final programmed
position, then the system may not produce the required path or the surface finish
accuracy. Hence, velocity feedback must be present along with the position
feedback whenever CNC system are used for contouring, in order to produce
correct interpolation and also specified acceleration and deceleration velocities.
The tacho generator used for velocity feedback is normally connected to the motor
and it rotates whenever the motor rotates, thus giving an analog output proportional
to the speed of motor. The analog voltage is taken as speed feedback by the servo-
controller and swift action is taken by the controller to maintain the speed of
the motor within the required limits.

Open-loop system
The open loop system lacks feedback. In this system, the CNC system send out
signals for movement but does not check whether actual movement is taking
place or not. Stepper motors are used for actual movement and the electronics of
these stepper motors is run on digital pulses from the CNC system. Since system
controllers have no access to any real time information about the system
performance, they cannot counteract disturbances appearing during the operation.
They can be utilized in point to point system, where loading torque on the axial
motor is low and almost constant.

Servo-drives

As shown in Fig.7.1.a the servo-drive receives signals from the CNC system
and transforms it into actual movement on the machine. The actual rate of
movement and direction depend upon the command signal from CNC system. There
are various types of servo-drives, viz., dc drives, ac drives and stepper motor
drives. A servo-drive consists of two parts, namely, the motor and the electronics for
drivingamotor.

25
Operator Control Panel
Fig.7.1.b shows a typical Hinumerik 3100 CNC system's operator control
panel. The operator control panel provides the user interface to facilitate a two-
way communication between the user, CNC system and the machine tool. This
consists of two parts:

 Video Display Unit (VDU)

 Keyboard

Video Display Unit (VDU)

The VDU displays the status of the various parameters of the CNC system and the
machine tool. It displays all current information such as:

 Complete information of the block currently being executed

 Actual position value, set or actual difference, current feed rate, spindle speed
 Active G functions
 Main program number, subroutine number
 Display of all entered data, user programs, user data, machine data, etc.
 Alarm messages in plain text
 Soft key designations

In addition to a CRT, a few LEDs are generally provided to indicate important

operating modes and status. Video display units may be of two types:

1. Monochrome or black and white displays

2. Color displays

26
Operator's and machine panel

Fig.7.1.d Operator control panel of Hinumerik 3100 system

27
Keyboard
A keyboard is provided for
the following purposes:

 Editing of part programs, tool data, and machine parameters.

 Selection of different pages for viewing.
 Selection of operating modes, e.g. manual data input.
 Selection of feed rate override and spindles speed override.
 Execution of part programs.
 Execution of other toll functions.

Machine Control Panel (MCP)

It is the direct interface between operator and the NC system, enabling the operation
of the machine through the CNC system. Fig.5 shows the MCP of Hinumerik 3100
system.

During program execution, the CNC controls the axis motion, spindle function or tool
function on a machine tool, depending upon the part program stored in the memory.
Prior to the starting of the machine process, machine should first be prepared with
some specific tasks like,

Establishing a correct reference point

Loading the system memory with the required part program
Loading and checking of tool offsets, zero offsets, etc.
For these tasks, the system must be operated in specific operating mode so that these
preparatory functions can be established.

28
Control elements of the machine control panel

Fig.7.1.(e) Machine control panel of hinumerik 3100

29
 CHAPTER-8
Modes of operation
8.1) MODE OF OPERATION

Generally, the CNC system can be operated

in the following modes:

 Manual mode
 Manual data input (MDI) mode
 Automatic mode
 Reference mode
 Input mode
 Output mode, etc

Manual mode: In this mode, movement of a machine slide can carried out
manually by pressing the particular jog button (+ or -). The slide (axis) is
selected through an axis selector switch or through individual switches (e.g., X+,
X-, Y+, Y-, Z+, Z-, etc.). The feed rate of the slide movement is prefixed.

CNC system allows the axis to be jogged at high feed rate also. The axis movement
can also be achieved manually using a hand wheel interface instead of jog
buttons. In this mode slides can be moved in two ways:
 Continuous
 Incremental

Continuous mode: In This mode, the slide will move as long as the jog button is
pressed.

Incremental mode: Hence the slide will move through a fixed distance,
which is selectable. Normally, system allows jogging of axes in 1, 10, 100, 1000,
10000, increments. Axis movement is at a prefixed feed rate. It is initiated by
pressing the proper jog+ or jog- key and will be limited to the no of
increments selected even if the jog button is continuously pressed. For subsequent
movement the jog button has to be released and once again pressed.

30
Manual Data Input (MDI) Mode
In this mode the following operation can be performed:

 Building a new part program

 Editing or deleting of part program stored in the system memory

Entering or editing or deleting of:

------ Tool offsets (TO)

------ Zero offsets (ZO)

------ Test data, et

Teach-in
Some system allows direct manual input of a program block and execution of the
same. The blocks thus executed can be checked for correctness of dimensions
and consequently transferred into the program memory as part program

Playback
In setting up modes like jog or incremental, the axis can be traversed either through
the direction keys or via the hand wheel, and the end position can be transferred into
the system memory as command values. But the required feed rates, switching
functions and other auxiliary functions have to be added to the part program in
program editing mode.

Thus, teach-in and playback operating method allows a program to created during
the first component prove out.

31
 Automatic Mode (Auto and Single Block)

In this mode the system allows the execution of a part program continuously. The
part program is executed block by block. While one block is being executed, the next
block is read by the system, analyzed and kept ready for execution. Execution of the
program can be one block after another automatically or the system will execute a
block, stop the execution of the next block till it is initiated to do so (by pressing the
start button). Selection of part program execution continuously (Auto) or one block at
a time (Single Block) is done through the machine control panel.

Many systems allow blocks (single or multiple) to be retraced in the opposite

direction. Block retrace is allowed only when a cycle stop state is established. Part
program execution can resume and its execution begins with the retraced block.
This is useful for tool inspection or in case of tool breakage. Program start can be
effected at any block in the program, through the BLOCK SEARCH facility.

Reference Mode

Under this mode the machine can be referenced to its home position so that all the
compensations (e.g., pitch error compensation) can be properly applied. Part
programs are generally prepared in absolute mode with respect to machine zero.
Many CNC systems make it compulsory to reference the slides of the machine to
their home positions before a program is executed while others make it optional.

32
 Input Mode and Output Mode (I/O Mode)

In this mode, the part programs, machine setup data, tool offsets, etc. can be
loaded/unloaded into/from the memory of the system from external devices like
programming units, magnetic cassettes or floppy discs, etc. During data input, some
systems check for simple errors (like parity, tape format, block length, unknown
characters, program already present in the memory, etc.). Transfer of data is
done through a RS232C or RS422C port.

Other Peripherals
These include sensor interface, provision for communication equipment,
programming units, printer, tape reader/puncher interface, etc.

Fig.8.1.a gives an overview of the system with few peripheral devices.

Programmable Logic Controller (PLC)

A PLC matches the NC to the machine. PLCs were basically introduced as

replacement for hard wired relay control panels. They were developed to be
reprogrammed without hardware changes when requirements were altered and
thus are reusable. PLCs are now available with increased functions, more
memory and large input/output capabilities.
Fig.7 gives the generalized PLC block diagram.
In the CPU, all the decisions are made relative to controlling a machine or a
process. The CPU receives input data, performs logical decisions based upon stored
programs and drives the outputs. Connections to a computer for hierarchical control
are done via the CPU.

The I/O structure of the PLCs is one of their major strengths. The inputs can be push
buttons, limit switches, relay contacts, analog sensor, selector switches, proximity
switches, float switches, etc. The outputs can be motor starters, solenoid valves,
position valves, relay coils, indicator lights, LED displays, etc.

The field devices are typically selected, supplied and installed by the machine tool
builder or the end user. The voltage level of the field devices thus normally
determines the type of I/O. So, power to actuate these

32
devices must also be supplied external to the PLC. The PLC power supply is
designated and rated only to operate the

internal portions of the I/O structures, and not the field devices. A wide
variety of voltages, current capacities and types of I/O modules are available.

33
INTERFACING
Interconnecting the individual elements of both the machine and the CNC
system using cables and connectors is called interfacing.
Extreme care should be taken during interfacing. Proper grounding in electrical
installation is most essential. This reduces the effects of interference and guards
against electronic shock to personnel. It is also essential to properly protect the
electronic equipment.
Cable wires of sufficiently large cross-sectional area must be used. Even though
proper grounding reduces the effect of electrical interference, signal cable requires
additional protection. This is generally achieved by using shielded cables. All the
cable shields must be grounded at control only, leaving other end free. Other noise
reduction techniques include using suppression devices, proper cable separation,
ferrous metal wire ways, etc. Electrical enclosures should be designed to provide
proper ambient conditions for the controller.
MONITORING
In addition to the care taken by the machine tool builder during design and
interfacing, basic control also includes constantly active monitoring functions. This
is in order to identify faults in the NC, the interface control and the machine at an
large stage to prevent damages occurring to the work piece, tool or machine. If a
fault occurs, first the machining sequence is interrupted, the drives are stopped, the
cause of the fault is stored and then displayed as an alarm. At the same time, the
PLC is informed that an NC alarm exits. In Hinumerik CNC system, for example,
the following can be monitored:
 Read-in

 Format
 Measuring circuit cables
 Position encoders and drives
 Contour
 Spindle speed
 Enable signals
 Voltage

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  Temperature
 Microprocessors
 Data transfer between operator control panel and logic unit
 Transfer between NC and PLC
 Change of status of buffer battery
 System program memory
 User program memory
 Serial interfaces

DIAGNOSTICS
The control will generally be provided with test assistance for service purposes
in order to display some status on the CRT such as:

Interface signals between NC and PLC as well as between PLC and machine
Flags of the PLC
Timers of the PLC
Counters of the PLC
Input/output of the PLC
For the output signals, it is also possible to set and generate signal combinations for
test purposes in order to observe how the machine react to a changed signal. This
simplifies trouble shooting considerably.

MACHINE DATA
Generally, a CNC system is designed as a general-purpose control unit, which has to
be matched with the particular machine to which the system is interfaced. The CNC
is interfaced to the machine by means of data, which is machine specific. The NC and
PLC machine data can be entered and changed by means of external equipment or
manually by the keyboard. These data are fixed and entered during commissioning of
the machine and generally left unaltered during machine operations.

Machine data entered is usually relevant to the axis travel limits, feed rates,
rapid traverse speeds and spindle speeds, position control multiplication factor, Kv
factor, acceleration, drift compensation, adjustment of reference point, backlash
compensation, pitch error compensation, etc. Also the optional features of the control

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m are made available to the machine tool builder by enabling some of the bits of
machine data.

COMPENSATIONS FOR MACHINE ACCURACY

Machine accuracy is the accuracy of the movement of the carriage, and is

influenced by:

(a) Geometric accuracy in the alignment of the slide ways

(b) Deflection of the bed due to load
(c) Temperature gradients on the machine
(d) Accuracy of the screw thread of any drive screw and the amount of backlash
(lost motion)
(e) Amount of twist (wind up) of the shaft which will influence the measurement
of rotary transducers

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 CHAPTER-9
PLC PROGRAMMING
9.1) PLC PROGRAMING

The principle of operation of a PLC is determined essentially by the PLC

program memory, processor, inputs and outputs.

The program that determines PLC operation is stored in the internal PLC
program memory. The PLC operates cyclically, i.e. when a complete program has
been scanned; it starts again at the beginning of the program. At the beginning of
each cycle, the processor examines the signal status at all inputs as well as the
external timers and counters and are stored in a process image input (PII).
During subsequent program scanning, the processor the accesses this process
image.

To execute the program, the processor fetches one statement after another from the
programming memory and executes it. The results are constantly stored in the
process image output (PIO) during the cycle. At the end of a scanning cycle, i.e.
program completion, the processor transfers the contents of the process image output
to the output modules and to the external timers and counters. The processor
then begins a new program scan.

STEP 5 programming language is used for writing user programs for

SIMATIC S5 programmable controllers. The program can be written and entered
into the programmable controller as in:

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  Statement list (STL)
 Control system flowchart (CSF)
 Ladder diagram (LAD)

The statement list describes the automation task by means of mnemonic function
designations.

The control system flowchart is a graphic representation of the automation task.

The ladder diagram uses relay ladder logic symbols represent the automation task.

The statement is the smallest STEP 5 program component. It consists of the

following:

Operation, i.e. what is to be done?

A = AND operation (series connection) O= OR operation (parallel connection)

E.g. :
S= SET operation (actuation)

Operand, i.e. what is to be done with?

E.g. I 4.5, i.e. with the

signal of input 4.5

The operand consists of:

Operand identifier (I = input, Q = output, F = flag, etc.)

Parameter, i.e. the number of operand identifiers addressed by the statement.

For inputs, outputs and flags (internal relay equivalents), the parameter consists
of the byte and bit addresses, and for timers and counter, byte address only.

The statement may include absolute operands, e.g. I 5.1, or symbolic operand, e.g. I
LS1. Programming is considerably simplified in the later case as the actual plant
designation is directly used to describe the device connected to the input or output.

Typically, a statement takes up one word (two bytes)

in the program memory.

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9.2-STRUCTURED PROGRAMMING

The user program can be made more manageable and straightforward if it is

broken down into relative sections. Various software block types are available for
constructing the user program.

Program blocks (PB) contain the user program broken down into technologically
or functionally related sections (e.g. program block for transportation, monitoring,
etc.). Further blocks, such as program blocks or function blocks can be called from a
PB.

Organization blocks (OB) contain block calls determining the sequence in

which the PBs are to be processed. It is therefore possible to call PBs
conditionally (depending on certain conditions).

In addition, special OBs can be programmed by the user to react to

interruptions during cyclic programming processing. Such an interrupt can be
triggered by a monitoring function if one or several monitored events occur.

Function block (FB) is block with programs for recurrent and usually complex
function. In addition to the basic operations, the user has a extended operation at his
disposal for developing function blocks. The program in a function block is
usually not written with absolute operands (e.g. I 1.5) but with symbolic
operands. This enables a function block to be used several times over with different
absolute operands.

For even more complex functions, standard function blocks are available from a
program library. Such FBs are available, e.g. for individual controls, sequence
controls, messages, arithmetic operations, two step control loops, operator
communications, listing, etc. These standard FBs for complex functions can
be linked it the user program just like user written FBs simply by means of
a call along with the relevant parameters.

The Sequence block (SB) contain the step enabling conditions, monitoring times
and conditions for the current step in sequence cascade. Sequence blocks

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 are employed, for example, to organize the sequence cascade in communication
with a standard FB.

The data blocks (DB) contain all fixed or variable

data of the user program

9.3-CYCLIC PROGRAM PROCESSING

The blocks of the user program are executed in the sequence in which they
specified in the organisation block.

9.4-INTERRUPT DRIVEN PROGRAM PROCESSING

When certain input signal changes occur, cyclic processing is interrupted at the next
block boundary and an OB assigned to this event is started. The user can formulate
his response program to this interrupt in the OB. The cyclic program execution is the
resumed from the point at which it was interrupted.

9.5-TIME CONTROLLED PROGRAM EXECUTION

Certain Obs are executed at the predetermined time intervals (e.g. every 100ms,
200ms, 500ms, 1s, 2s, and
5s). For this purpose, cyclic program execution is interrupted at the block boundary
and resumed again at this point, once the relevant OB has been executed.
Fig.9.5.a gives the organisation and execution of a structured user program.

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9.6-EXAMPLES OF PLC PROGRAM

Before attempting to write a PLC program, first go through the instruction set of
the particular language used for the equipment, and understand the meaning of
each instruction. Then study how to use these instructions in the program
(through illustration examples given in the manual). Once the familiarization task
is over, then start writing the program.

Follow the following steps to write a PLC program.

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 List down each individual element (field device) on the machine as Input/Output.

Indicate against each element the respective address as identifier during electrical
interfacing of these elements with the PLC.

Break down the complete machine auxiliary functions that are controlled by the

PLC into individual, self contained functions.

Identify each individual function as separate block (PBxx/FBxx)

Once the PBs and FBs for each function are identified, take them one by one for
writing the program.

List down the preconditions required for the particular function separately.

Note down the address of the listed elements.

Write down the flow chart for the function.

Translate the flow chart into PLC program using the

instructions already familiarized.

Complete the program translation of all individual functions in similar lines.

Check the individual blocks independently and correct the program to

get the required results.

Organize all the program blocks in the organization block depending upon the
sequence in which they are supposed to be executed as per the main machine
function flow chart.
Check the complete program with all the blocks incorporated in the final program.

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 CHAPTER-10
CONCLUSION

The industrial training at BHEL Haridwar helped us in improving our

practical knowledge and awareness regarding CNC machines to a large extent.
Here we came to know about the technology and material used in manufacturing
of CNC machines. Besides this, we also visualized the parts involved or
equipments used in the power generation.

Here we learnt about how the electrical equipments are being manufactured and how
they tackle the various problems under different circumstances. At least we could
say that the training at BHEL Haridwar is great experience for us and it really
helped us in making or developing our knowledge about CNC machines and other
equipment used in power generation.

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 REFERENCES

Books
A text book of electrical machines by P.S.BIMBRA
A text book of electrical technology by B.L.THERAJA

Other
BHEL Internal material

Sites
http://www.bhel.com
http://en.wikipedia.org/wiki/Turbo_generator
http://en.wikipedia.org/wiki/Hydrogen-cooled_turbogenerator

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