Project Report

On
Programmable Logic Controllers
At
Usha Martin Limited
(Wires Ropes & Specialty Products Division)
From 15th Jan, 2024 to 27th Jan, 2024

Submitted By :
Name – Anurag Kumar ľhakur(EEE)
Institute- B.V.C.O.E (New Delhi)
Roll No- 01711504921
 ACKNOWLEDGEMENľ

This Research was supported by Mr. Kunal Parashar

(Manager, Electrical Projects) & Mr. RK Singh(GM,
Head Electricals). His guidance & support helped me to
carry this project successfully . I am thankful to them
who helped me to complete this project.

I am also grateful to Mr. Arvind Kumar(HOD, HRD) for

assistance with a technique and allotting me this project
for winter training and giving this chance to improve and
enhance our knowledge gained so,
I would like to thank all employees of Usha Martin for
their support.

(Kunal Parashar)
Manager
 Contents

 USHA MARTIN LIMITED

 VISION OF THE COMPANY
 SPECIALITIES
 WIRE/WIRE-ROPE BUSINESS
 STRAND
 QUALITY & TESTING
 PRODUCTS & SERVICE OFFERED
INTRODUCTION TO Programmable Logic
Controllers
TRANSFORMERS
 BIBLIOGRAPHY
 USHA MARľIN LIMIľED

Usha Martin Ranchi Facility is one of the world’s largest

wire rope manufacturing facility under one roof . Spread
across an area of more than 100 acres , Usha Martin
Ranchi employs more than 1,700 people. This is the first
facility established by Usha Martin since its inception in
1961.
Wire rods are processed through modern pickling
facilities , patenting & galvanizing facilities , wire
drawing facilities and strand & rope making facilities to
produce wires , strands and wire ropes for multiple
applications .
This wire ropes produced in this plant find application in
Oil and offshore, Mining , Crane, Elevator , Aerial
Ropeway and Bridges all over the world . The inhouse
rope designing and testing capabilities facilitate fast
development of new types of ropes . It also has a modern
Machinery division which produces machines for Usha
Martin and other customers.
This plant is certified with ABS Manufacturing
Certification ,ABS Certificate for design assessment ,
API Certificate , DNV Certificate , ISO 9001- 2008.
 VISION OF THE COMPANY

The company vision is To be the global leader of the

wire rope industry and wire & wire ropes manufacturer
in India , by delivering customer delight ,adopting
modern technology and ensuring sustainable , inclusive
growth for all of it’s stakeholders”.
This vision is manifested in the fully wire & wire rope
business model of the company.
 SPECIALITIES

Usha Martin is one of the largest manufacturers of wire & wire

ropes in the world . With a history of more than 50 years, the
company has global base of wire rope manufacturing with
facilities located in India, UK , Dubai and Bangkok. For
specific products, Usha Martin has collaborated with globally
reputed companies like Gustav Wolf of Germany, Joh Pengg of
Austria and TESAC wire rope of Japan.
Usha Martin is amongst the largest wire rope
manufacturer in the world and a leading specialty wire
producer in India . The wire rope manufacturing
facilities located in India , UK ,UAE and Thailand
produce one of the widest range of wire ropes in the
world. Long standing in diverse sectors like Oil and
Offshore , Mining
, Crane , Elevator etc. A testimony of our expertise in
manufacturing high quality wire rope products.
They expertise in wire rope dates back to 1961 when
they setup their first rope manufacturing unit. Since then,
they relentlessly dedicated on stringent controls on
quality ,at each stage of manufacturing to produce wire
ropes , strands & wire They set up specialty steel plant
in 1974
.
 WIRE/WIRE-ROPE BUSINESS

The company is a global giant in wire rope industry,

with facilities in India (near Ranchi and Hoshiarpur,
Punjab), Workshop (UK) ,Aberdeen (UK)
,Rotterdam(The Netherlands),Dubai (UAE) and
Bangkok (Thailand). To remain close to customers. The
company has a wide network of offices in India , USA,
Europe, China ,South East Asia and Australia. The
company’s facilities are equipped with world class
machines and equipment to ensure the best quality
products for its customers.

These products find diverse applications such as oil &gas

, mining , crane, elevator, mining aerial , structural etc.
Some renowned projects where company has supplied its
wire rope include Lion’s gateway bridge(Canada),
Vidyasagar setu bridge (Kolkata, India) . Worlds’s
highest oil pipeline (Papua & New Guinea) etc.
RANCHI, INDIA ( Wires Ropes & Specialty
-Products Division)

Usha Martin at Tatisilwai near Ranchi is one of the

world’s largest wire rope manufacturing facility under
one roof . Spread across an area of 500 acres, this facility
employs more than 1,700 people.
Along with wire rope , this unit produces wires, LRPC
Strands, Cords , OT Wires, Slings, Pre Stressing
Products , Bright Bar and Engineering Machines . The
plant is equipped with a complete range of facilities such
as Patenting , Galvanizing, Drawing, Stranding and
closing machines for manufacturing of wire , strand,
Wire rope and Cord.
The facility is certified with ABS Manufacturing
Certification for design assessment, API Certificate,
DNV Certificate, ISO 9001-2008 (ANAB, UKAS), ISO
14001, Lloyd’s Certificate, NABL Certificate for
mechanical test & NABL certificate for chemical test.
The inhouse rope design facilities help this unit to
continuously improve the quality of ropes manufactured.
This facility received TPM certification from Japan
Institute of Plant Maintenance and is working towards
TQM (Total Quality Management).
 STRAND

Usha Martin’s continued investment in technology and

equipment has consistently pushed to the highest quality
standards. Our engineering excellence and our
commitment to customers is manifested in the wide
usage of our strands in the construction industry.
Usha Martin produces a comprehensive range of strands,
with each type designed to cater to specific requirements
of the industry:
 Bright low relaxation(LRPC) strand
 Normal Relaxation (NRPC) strand
 Galvanized LRPC strand
 Polymer coated Galvanized/ Bright LRPC strand.
 Grease/ Wax filled un-bonded LRPC strand.
 Bonded LRPC Strand
 Plain, Indented and ribbed high tensile wire for
prestressed concrete.
 QUALITY & TESTING

Usha Martin has a stage by stage testing program to

ensure that only the material meeting the stringent
quality norms enter the next process. The processes are
controlled according to the ISO Quality System.
Our products undergo test, Relaxation test, Torsion test
and Chain test depending upon the quality requirement.
With the stringent quality control measures Usha Martin
ensures to deliver the best quality products catering to
the criticality of the application.
 PRODUCTS & SERVICES OFFERED

 Wire Rope
 Wire
 Strand
 Conveyor Cord
 Pre-Stressing Products
 Slings
 Oil tempered Wire
 Machineries
INTRODUCTION TO
PROGRAMMABLE LOGIC
CONTROLLER -PLC

A programmable logic controller or PLC is more or less

a small computer with a built in operating system (OS).
This OS is highly specialized and optimized to handle
incoming events in real time, ie at the time of their
occurrence. The plc has input lines, to which sensors are
connected to notify of events (such as temperature
above/below a certain level, liquid level reached, etc)
and output lines, to which actuators are connected to
affect or signl reactions to the incoming events ( such as
start an engine, open/close a valve , and so on).
The system is user programmable. It uses a language
called “Realy Ladder” or RLL (Realay Ladder Logic).
The name of this language implies that the control logic
of the earlier days, which was built from relays, is being
simulated.
Some other languages used include:
1. Sequential Function Chart
2. Function Block Diagram
3. Structured Text
4. Instruction Text
A PLC is digital computer used for automation of
typically industrial electromechanical process.
PLC- PROGRAMMABLE LOGIC CONTROL
A programmable logic controller(PLC), or
programmable controller is an industrial digital
computer which has been ruggedized and adapted for the
control of manufacturing process, such as assembly line
or robotic devices, or any activity that requires high
reliability control and ease of programming and process
fault diagnosis.
They were first developed in the automobile in the
automatic industry to provide flexible, ruggedized and
easily programmable controllers to replace hard-wired
relays and timers.

Since then they have been widely adopted as high

reliability automation controllers suitable for harsh
environments. A PLC is an example of a “hard ’ real
time
system since output results must be produced in response
to input conditions within a limited time, otherwise
unintended operation will result.
THE NEED FOR PLCs :-
PLC is needed so as to have the following tasks:
1. To get the automation in process
2. Controlling of equipment with just one click.
3. Arranging so many controllers, microprocessor and
input-output modules
4. To make the efficient use of digital electronics and
control system.
5. Real time application of microcontrollers,
microprocessors and input-output modules.
6. In the industries , PLC may help to get the reduction
in manpower and wastage of raw materials.

Block Diagram of PLC arrangement

  HISTORY OF THE PLC

In 1968 GM Hydra-Matic: The automatic transmission

division of General Motors issued a request for
proposals for an electronic replacement for hard-wired
relay systems based on a white paper written by engineer
Edward R. Clark.
The winning proposal came from Bedford Associates of
Bedford, Massachusetts.
The first PLC designed the 084 because it was Bedford
Associates’ eighty-fourth project, was the result.
Bedford Associates started a new company dedicated to
developing, manufacturing, selling, and servicing this
new product: Modicon, which stood for MOdular
DIgital CONtroller.
One of the people who worked on that project was Dick
Morley, who is considered to be the father of the PLC.
Programmable Logic Controllers (PLCs) are industrial
computers designed to control and monitor processes in
automated systems. PLC architectures refer to the different
types of hardware components used in a PLC system, such
as controllers, input/output modules, communication
modules, and power supplies.
Each type of component has its own specific function in the
automation process. Choosing the right architecture for your
application maximizes performance while
reducing maintenance costs associated with automation systems.

An open architecture design allows the system to be

connected easily to devices and programs made by other
manufacturers.
A closed architecture or proprietary system is one
whose design makes it more difficult to connect devices
and programs made by other manufacturers.

 ADVANTAGES OF PLC
CONTROL SYSTEM:

 Very high accuracy

 Low power Consumption
 High level human safety
 Less Plan Running Cost
 Small in size (Required Lesser space)
 Rugged Construction
 Easily programmable
 Economical & high flexible
 Easy Documentation
 Easy Maintenance
  PLC SYSTEM

A programmable logic controller is a type of tiny computer that can rece

NOTE: When working with PLC systems that are

proprietary in nature we must be sure that any generic
hardware or software we use is compatible with our
particular PLC.
  HARDWARE

Typically a PLC system has the basic functional

components of processor unit, memory, power supply
unit, input/output interface section, communications
interface and the programming device

 The processor unit or central processing unit (CPU) is

the unit containing the microprocessor and this
interprets the input signals and carries out the control
actions, according to the program stored in it’s
memory, communicating the decisions as action
signals to the input.
 The power supply unit is needed to convert the mains
ac voltage to low dc voltage (5V) necessary for the
processor and the circuits in the input and the output
interface modules.
 The programming device is used to the enter the
required the program into the memory of the
processor. The program is developed in the device and
then transferred to the memory unit of PLC.

 The memory unit is where the program is stored that is

to be used for the control actions to be exercised by
the microprocessor and data stored from the input for
processing and for the output for outputting.

 The input and output sections are where the processor

receives information from external devices and
communicates information to external devices. The
inputs might thus be from switches as illustrated with
the automatic drill, or other sensors such as photo-
electric cells, as in the counter mechanism or
temperature sensors, or flow sensors, etc. The output
might to be motor starter coils, solenoid valves, etc.
Input and output devices can be classified as giving
signals which are discrete, digital, analogue devices
giving discrete or digital signals are ones where the
signals are either off or on. Thus a switch is a device
giving a discrete signal, either no voltage or a voltage
which give a sequence of on-off signals.
 The communications interface is used to receive and
transmit data on communications networks from one
to other remote PLCs. It is concerned with such
actions as device verification, data acquisition,
synchronization between user applications and
connection management.
  PLC INPUTS

The term PLC inputs refer to the devices and transducers

which are entrusted with taking in information about the
physical world to the PLC. PLC inputs also refer to the
PLC hardware that connects to those devices, sensors
and transducers. The PLC uses this input information to
make decisions based upon its program whether to
energize and de energize the outputs controlled by the
PLC.
It is very important to know about the different input
types discussed below.
The two types of PLC inputs are commonly referred to
DI and AI (Digital & Analog) input signal. Analog
inputs are those like temperature and pressure which
span over a range of values. Digital inputs are simply
two states, like those of a switch position indicating as
On or Off.
 Analog Inputs include temperature
sensors/transmitters, current sensors, voltage
sensors and other that can convert a physical
quantity to an electrical signal. These electrical
signals used for PLC inputs are typically 4-20mA or
1-5vdc.
 Digital Inputs include push-buttons, limit switches,
relay contacts, proximity switches, photo sensors
(On/Off), pressure switches and more. Digital inputs
 devices are available in both DC as well as AC and
some are voltage independent such as switch
contact.

APPLICATIONS OF PLC CONTROL SYSTEM

 Conveyor Belt
Consider a conveyor belt that is to be used to transport
goods from a loading machine to a packaging area.
When an item is loaded onto the conveyor belt, a contact
switch might be used to indicate that the item is on the
belt and start the conveyor motor. The motor then has to
keep running until item reaches the far end of the
conveyor and falls off into the pacakaging area. When it
does this, a switch might be activated which has the
effect of

switching off the conveyor motor. The motor is then to

remain off until the next item is loaded onto the belt.
Thus the inputs to a PLC controlling the conveyor are
from 2 switches and the output is to a motor.
 Lift

Consider a simple goods lift to move items from one

level to another. It might be bricks from the ground level
to the height where the brick layers are working. The lift
is to move upwards when a push button is pressed at the
upper level to request the lift to move upwards, but in
both cases there is a condition that has to be met that a
limit switch indicates that the access gate to the lift
platform is closed. The lift is to move downwards when
a push button is pressed at the upper level to send the lift
downwards or a push button is pressed at the lower level
to request the lift to move upwards, but in both cases
there is a condition that has to be met that a limit switch
indicates that the access gate to the lift platform is
closed. Thus the inputs to the control system are
electrical on-off signals from push button switches and
limit switches. The output from the control system is the
signal to control the motor.

 Liquid level monitoring

It shows a method that could be used to give an on-off

signal when the liquid in a container reaches a critical
level. A magnetic float, a ring circling the sensor probe,
fails as the liquid level falls and opens a reed switch
when the critical level is reached. The reed switch is in
series with a 39 ohm resistor so that this is switched in
parallel with a 1k ohm resistor by the action of the reed
switch. Opening the reed switch thus increases the
resistance from 37 ohm to 1 kohm . Such a resistive
change can be transformed by signal conditioning on/off
signals.
In Usha Martin, PLCs are used in following ways:
 Wire drying machines
 Stranding and closing machines
 Furnace
 Testing machines
ON FIELD PICTURE OF PLC PANEL
 TRANSFORMER
Transformer, device that transfers electric energy from
one alternating current circuit to one or more circuits
other circuits, either increasing(stepping up) or reducing
(stepping down) the voltage. Transformer are employed
for widely varying purposes eg- to reduce the voltage of
conventional power circuits to operate low voltages
device, such as doorbells and toy electric trains, and to

raise the voltage from electric generators so that electric

power can be transmitted over long distances.
Transformer is basically a voltage control device that is
used widely in the distribution and transmission of
alternating current power. The idea of a transformer was first
discovered by Michael Faraday in the year 1831 and was
 carried forward by many other prominent science
scholars. However , the general purpose of using
transformers was to maintain a balance between the
electricity that was generated at very high voltage and
consumption which was done at very low voltages.
The transformer works on the principle of
electromagnetic induction and mutual induction.
WORKING PRINCIPLE OF TRANSFORMER

The transformer works on the principle of Faraday’s

Law of electromagnetic induction and mutual induction.
There are usually two coils primary and secondary coil
on the transformer core. The core laminations are joined

in the form of strips. The two coils have high mutual

inductance. When an alternating current passes through
the primary coil, it creates
a varying magnetic flux induces an EMF (electromotive
force) in the secondary coil, which is linked to the core
having a
primary coil. This is mutual induction.

Overall a transformer carries out the following

operations:
1-Transfer of electrical energy from one circuit to
another.
2-Transfer of electrical power through electromagnetic
induction.
3-Electric power transfer without any change in the
frequency.
IDEAL TRANSFORMER
The ideal transformer has no losses. There is no
magnetic leakage flux, ohmic resistance in it’s windings
and no iron losses in the core. The flux formed is a
sinusoidal wave. It rises to a maximum value of $m
and decreases to a negative maximum of $m. So flux
reaches a maximum in one-quarter of a cycle . The time
taken is equal to T/4.

VOLTAGE TRANSFORMATION RATIO

E1/N1 = E2/N2 = k
Where K is called the voltage transformation ratio,
which is a constant.
Case1: If N2 > N1 , K>1 , it is called a step up
transformer.
Case2: If N2 < N1 , K<1 , it is called a step down
transformer.
TRANSFORMER EFFICIENCY
Comparing system output with the input will confirm the
transformer efficiency. The system is called better when
its efficiency is high.
Efficiency(n) = Output power/ Input power * 100
Or Efficiency (n) = P out / P out+ P losses * 100

APPLICATIONS OF TRANSFORMER:

1. The transformer transmits electrical energy through

wires over long distances.
2. Transformer with multiple secondaries are used in
radio and TV receivers, which require several different
voltages.
3. Transformers are used as voltage regulators.
SINGLE LINE DIAGRAM OF USHA MARTIN
 BIBLIOGRAPHY

For successfully completing my project file. I have taken

help from :
 WIKIPEDIA
 Electrical geeks
 Advanced PLC programming by Avinash Malekar
 Power Distribution Transformers by K.R.M Nair

I am specially thankful to Mr. Kunal Parashar Sir for

guiding me in this project.

Submitted By :

Name – Anurag Kumar ľhakur

Branch- Electrical & Electronics
Engg Institute- B.V.C.O.E (New Delhi)
Roll No- 01711504921