Smoke&Gas With PLC Project1-Modified

1
Smoke
&
Gas
detection
Monitoring
and
Control
using
PLC
(Programmable Logic Controller):

ACKNOWLEDGMENT:
This Project has been developed with the involvement and assistance of
several people who are responsible in the completion of this project.
Hereby we would like to acknowledge the effort of all the sources (lecturer
and our project guide) which were incorporated in our project. We are
thankful to the Head of our department Dr. M.P. Soni who has been a
source of inspiration to us right from the inspection of our project,
providing us with valuable suggestions and key notes in our project
seminar.
His
unending
quench
for
maximizing
the
scope
and
opportunities for the betterment of students has been inspiring to us to

do better in our project. We are also grateful to our project guide
Mr. Mohd. Abdul Muqeet for his valuable suggestions. His profound
knowledge on the subject of PLC and its Applications
has been helpful
throughout. We owe our deepest gratitude to our faculty adviser

Mr. Shaik Abdul Qadeer for his immense faith in our project and also for
his support in providing us with technical as well as nontechnical
assistance. We would also like to thank our Lab Technician
Mr. A. David.F.Krishow for his support. Our project would not have
been possible without the support, guidance and assistance of
Mr. Ahmed M.A and Mr. Hanumantha Rao.C from Avidus Engineering
Pvt. Ltd, who has shown relentless efforts in educating us throughout
the process in various ways apart from working with us in making our
project success.
Monitoring and Controlling of Smoke emission and Gas Leakage using PLC
Lastly we would like to offer our regards to all those who have supported
us in any respect during the completion of our project.
ABSTRACT
The Project is to study Smoke and Gas detector Systems with PLC
(Programmable Logic Control).
Smoke Detector System:
Smoke detector system is essential for Industrial and Commercial
facilities. It detects accidental fire and spray water on the source of fire to
quench it. They include different type of smoke detectors, both
addressable and conventional and Fire Alarm Control Panel (FACP). In
the current project in place of FACP, Programmable Logic Controller
(PLC) used for Logic development.
Gas Detector System:
Gas detector system is essential for detecting flammable and poisonous
gases
in
Industrial
facilities
and
HVAC
(Heating
Ventilation
Air
Conditioning) systems.
Programmable Logic Controller:
Programmable Logic Controller is a digitally operated electronic system,
designed
for
use
in
an
industrial
environment,
which
uses
programmable memory for the internal storage of user-orientated

instructions
for
implementing
specific
functions
such
as
logic
sequencing, timing, counting, & arithmetic to control, through digital or

analog inputs & outputs, various types of machines or processes. Both
the PLC & its associated peripherals are designed so that they can be
easily integrated into an industrial control system & easily used in all
their intended functions.
Incoming control signals, or inputs, interact with instructions specified
in the user ladder program, which tells the PLC how to react with the
incoming signals. The user program also directs the PLC on how to
control field devices like motor starters, pilot lights, & solenoids. A signal
going out of the PLC to control a field device is called an Output.
TABLE OF CONTENTS
CHAPTER
PAGE NUMBER
ACKNOWLEDGEMENT
ABSTRACT
Chapter 1: Introduction
1.1Project Overview
1.2 Introduction to Smoke Detector
12
1.2.1 Conventional type
12
1.2.2 Addressable type

1.3Introduction to Gas Detector
15
1.3.1 Gas hazarda
15
1.3.2 Typical areas that require gas detection
18
1.3.3 Gas detection
22
1.3.4 Location of Sensors
26
1.4 Control systems and Mitigation
27
1.4.1 Fire alarm Control Panels
30
1.5 PLC(PROGRAMMABLE LOGIC CONTROLLER)
44
1.5.1 Introduction to PLC
44
1.5.2 PLC Advantages and Disadvantage
45
1.5.3 Allen Bradley PLC Micrologic 1200 Controller
46
CHAPTER 2: HARDWARE DESCRIPTION
52
2.1 Block Diagram
52
2.2 Wiring Diagram
55
2.3 Smoke Sensor
56
2.3.1 Product Introduction
56
2.3.2 Product profile
56
2.4 Gas Detector
57
2.4.1 Sensitivity
57
2.4.2 Specifications
58
2.4.3 Gases Detected
58
2.5 Pump, Solenoid Valve, Fan, Relays
58
CHAPTER 3: PLC PROGRAMMING
60
3.1 Introduction
60
3.2Programming Languages
63
3.3 Ladder Logic Structure
67
3.4 Ladder Logic Programming Basic Instructions
69
CHAPTER 4:LOGIC DEVELOPMENT
73
4.1 Electrical circuit-Logic diagram relationship
77
4.2 Introduction
78
4.3 Ladder Diagram Symbols
78
4.4 Developing a ladder diagram
81
4.5 Automatic Mode of Operation
83
4.6 Ladder Diagram Analysis
85
4.7 Developing the PLC Program Logic
86
4.8 Power Supply Section
87
4.9.1Full Wave Rectifier
87
4.9.2 Full Wave Bridge Rectifier
89
CHAPTER 5: PROJECT PICTORIAL
95
REPRESENTATION
5.1 Project PLC Programming Pictorial
101
Representation
CHAPTER 6: ADVANTAGES AND LIMITATIONS
106
6.1 Advantages
106
6.2 Limitations
107
6.3 Conclusion
108
BIBLOGRAPHY
109
LIST OF FIGURES:
Figure
Page number
Fig 1: Inside view of Smoke Detector
10
Fig 2: Observation Relays
11
Fig 3: Smoke Detector Installation
12
Fig 4: Installation and placement
14
Fig 5: Horn & Beacon
28
Fig: 6 Wiring Diagram
32
Fig: 7 Addressable FACP
33
Fig: 8 System Functions
37
Fig 9: Fire alarm panel, showing drill switch
38
Fig 10: Allen Bradley PLC Architecture
49
Fig11: Block Diagram
52
Fig 12: Project Perspective-1
53
Fig 13: Project Perspective-2
54
Fig 14: Wiring Diagram
55
Fig 15: LPG Gas Detector
57
Fig 16: PLC Rack
61
Fig 17: PLC Operatation
62
Fig 18: Basic Components of SFC Lanuguage
65
Fig 19: Basic Components of FBD Language
67
Fig 20: Timer & Counter
70
Fig 21: Three types of Logic representation
72
Fig 22: Positive Logic
74
Fig 23: AND Symbol
75
Fig 24: OR Symbol
76
Fig 25: Inverting Circuit
77
Fig 26: Reset Operation
77
Fig 27: Electrical Interlock Circuit
78
Fig 28: Symbol used Ladder Diagrams
80
Fig 29: Automatic Control of a pressurized water
82
tank
Fig
Fig
Fig
Fig
Fig
Fig
30:
31:
32:
33:
34:
35:
Full Wave Rectifier Circuit

Diode Bridge Rectifier
Positive Half-Cycle
Negative Half-cycle
Typical Bridge Rectifier
Full-wave Rectifier with Smoothing
88
90
90
91
91
92
Capacitor
Fig 36: Full wave Rectifier
Fig 37: Project Model with PLC
Fig 38: Project Model View-1
Fig 40: PLC Trainer
Fig 43: Programming Screen Shot-1
93
95
96
97
98
99
100
101
Fig 44: Programming Sreen Shot-2
102
103
104
105
Chapter1: Introduction:
1.1 Project Overview:
The Project is the study of Smoke and Gas detector systems with PLC
(Programmable Logic Controller).
The Project includes Smoke and Gas detectors, fan, pump, and solenoid
valve activation. The logic is developed in the Allen Bradley PLC
(Programmable Logic Controller).
A Smoke detector was installed on a chamber, when it senses the smoke;

it actuates a water pump and solenoid valve to spray water at the smoke
emanating area to extinguish if any fire is there.
A Gas detector was installed in a chamber. When it detects the gas, it
actuates a exhaust fan to remove all the poisonous or flammable gas
from the chamber.
The smoke detector powered by 9 V battery and gives analog signal of
15mA when it detects the smoke. It is connected to PLC (Programmable
Logic Controller) as analog input.
The Gas detector powered by 9v battery and gives potential free contact
(Normally open NO) as digital input to PLC (Programmable Logic
Controller). When it detects the gas the NO contact closes.
1.2 Introduction to Smoke Detector

Smoke detector
A smoke detector is a device that detects smoke, typically as an
indicator of fire. Commercial, industrial, and mass residential devices
issue a signal to a fire alarm system, while household detectors, known
as smoke alarms, generally issue a local audible or visual alarm from the
detector itself.
Smoke detectors are typically housed in a disk-shaped plastic enclosure
about 150 millimeters (6 in) in diameter and 25 millimeters (1 in) thick,
but the shape can vary by manufacturer or product line. Most smoke
detectors work either by optical detection (photoelectric) or by physical
process (ionization), while others use both detection methods to increase
sensitivity to smoke. Sensitive alarms can be used to detect, and thus
deter, smoking in areas where it is banned such as toilets and schools.

Smoke
detectors in large commercial,
industrial, and residential
buildings are usually powered by a central fire alarm system, which is

powered by the building power with a battery backup. However, in many
single family detached and smaller multiple family housings, a smoke
alarm is often powered only by a single disposable battery.
Fig1: Inside view of Smoke Detector
Inside a basic ionization smoke detector. The black, round structure at

the right is the ionization chamber. The white, round structure at the
upper left is the piezoelectric buzzer that produces the alarm sound
An ionization type smoke detector is generally cheaper to manufacture
than an optical smoke detector; however, it is sometimes rejected because
it is more prone to false (nuisance) alarms than photoelectric smoke
detectors.[2][3] It can detect particles of smoke that are too small to be
visible.
It
includes
about
37 kBq or
1 Ci of
radioactive
element americium-241 (241Am), corresponding to about 0.3 g of the

isotope. The radiation passes through an ionization chamber, an air-filled
space between two electrodes, and permits a small, constant current
between the electrodes. Any smoke that enters the chamber absorbs the
10
alpha particles, which reduces the ionization and interrupts this current,
setting off the alarm.
An alpha emitter, has a half-life of 432 years. Alpha radiation, as
opposed to beta and gamma, is used for two additional reasons: Alpha
particles have high ionization, so sufficient air particles will be ionized for
the current to exist, and they have low penetrative power, meaning they
will be stopped by the plastic of the smoke detector or the air.
Obscuration is a unit of measurement that has become the standard
definition of smoke detector sensitivity. Obscuration is the effect that
smoke has on reducing sensor visibility; higher concentrations of smoke
result in higher obscuration levels.
Typical smoke detector obscuration ratings[9]

Type of Detector Obscuration Level
Ionization
2.65.0% obs/m (0.81.5% obs/ft)
Photoelectric
6.513.0% obs/m (24% obs/ft)
Beam
3% obs/m (0.9% obs/ft)[citation needed]
Aspirating
0.00520.5% obs/m (0.00156.25% obs/ft)
Laser
0.066.41% obs/m (0.022.0% obs/ft)[10]
Fig 2: Observation Relays
Commercial
smoke
detectors
are
either
conventional
or
analog
addressable, and are wired up to security monitoring systems or fire

alarm control panels (FACP). These are the most common type of
detector, and usually cost a lot more than a household smoke alarms.
They exist in most commercial and industrial facilities, such as high
rises, ships and trains. These detectors don't need to have built in
11
alarms, as alarm systems can be controlled by the connected FACP,

which will set off relevant alarms, and can also implement complex
functions such as a staged evacuation.
1.2.1Conventional
The word "conventional" is slang used to distinguish the method used to
communicate with the control unit from that used by addressable
detectors whose methods were unconventional at the time of their
introduction. So called Conventional Detectors cannot be individually
identified by the control unit and resemble an electrical switch in their
information capacity. These detectors are connected in parallel to the
signaling path or (initiating device circuit) so that the current flow is
monitored to indicate a closure of the circuit path by any connected
detector when smoke or other similar environmental stimulus sufficiently
influences any detector. The resulting increase in current flow is
interpreted and processed by the control unit as a confirmation of the
presence of smoke and a fire alarm signal is generated.
1.2.2Addressable
Fig 3: Smoke Detector Installation
12
An addressable Simplex smoke detector

This type of installation gives each detector on a system an individual
number, or address. Thus, addressable detectors allow an FACP, and
therefore fire fighters, to know the exact location of an alarm where the
address is indicated on a diagram.
Analog addressable detectors provide information about the amount of
smoke in their detection area, so that the FACP can decide itself, if there
is an alarm condition in that area (possibly considering day/night time
and the readings of surrounding areas). These are usually more
expensive than autonomous deciding detectors
Standalone smoke alarms
The main function of a standalone smoke alarm is to alert persons at
risk.
Several
specifications
methods
published
are
used
and
documented
by Underwriters
in
industry
Laboratories[12] Alerting
methods include:
Audible tones
Usually around 3200 Hz due to component constraints (Audio

advancements for persons with hearing impairments have been
made;
85 dBA at 10 feet
Spoken voice alert
Visual strobe lights
13
110 candela output
Fig:4 Installation and placement
In
new
construction,
minimum
requirements
are
typically
more
stringent. All smoke detectors must be hooked directly to the electrical

wiring, be interconnected and have a battery backup. In addition, smoke
detectors are required either inside or outside every bedroom, depending
on local codes. Smoke detectors on the outside will detect fires more
quickly; assuming the fire does not begin in the bedroom, but the sound
14
of the alarm will be reduced and may not wake some people. Some areas
also require smoke detectors in stairways, main hallways and garages.
1.3Introduction to Gas Detector

What is gas?
The name gas comes from the word chaos. Gas is a swarm of molecules
moving randomly and chaotically, constantly colliding with each other
and anything else around it. Gases fill any available volume and due to
the very high speed at which they move will mix rapidly into any
atmosphere in which they are released.
Industrial processes increasingly involve the use and manufacture of
highly dangerous substances, particularly flammable, toxic and oxygen
gases. Inevitably, occasional escapes of gas occur, which create a
potential hazard to the industrial plant, its employees and people living
nearby. Worldwide incidents, involving asphyxiation, explosions and loss
of life, are a constant reminder of this problem.
In most industries, one of the key parts of any safety plan for reducing
risks to personnel and plant is the use of early-warning devices such as
gas detectors. These can help to provide more time in which to take
remedial or protective action. They can also be used as part of a total,
integrated monitoring and safety system for an industrial plant.
1.3.1Gas Hazards
15
There are three main types of gas hazard: Flammable, Toxic and
Asphyxiant
Flammable Gas Hazards
Combustion is a fairly simple chemical reaction in which oxygen is
combined rapidly with another substance resulting in the release of
energy. This energy appears mainly as heat sometimes in the form of
flames.
The
igniting
substance
is
normally,
but
not
always,
Hydrocarbon compound and can be solid, liquid, vapor or gas. However,

only gases and vapors are considered in this publication.
Flammable Limit
There is only a limited band of gas/air concentration which will produce
a combustible mixture. This band is specific for each gas and vapor and
is bounded by an upper level, known as the Upper Explosive Limit (or the
UEL) and a lower level, called the Lower Explosive Limit (LEL). At levels
below the LEL, there is insufficient gas to produce an explosion (i.e. the
mixture is too lean), whilst above the UEL, the mixture has insufficient
oxygen (i.e. the mixture is too rich). The flammable range therefore falls
between the limits of the LEL and UEL for each individual gas or mixture
of gases. Outside these limits, the mixture is not capable of combustion.
The Flammable Gases Data in section 2.4 indicates the limiting values
for some of the better-known combustible gases and compounds. The
data is given for gases and vapors at normal conditions of pressure and
temperature. An increase in pressure, temperature or oxygen content will
generally broaden the flammability range. In the average industrial plant,
16
there would normally be no gases leaking into the surrounding area or,
at worst, only a low background level of gas present. Therefore 5
Flammable Gas Hazards Flammable Limit There is only a limited band of
gas/air concentration which will produce a combustible mixture. This
band is specific for each gas and vapor and is bounded by an upper level,
known as the Upper Explosive Limit (or the UEL) and a lower level, called
the Lower Explosive Limit (LEL). the detecting and early warning system
will only be required to detect levels from zero percent of gas up to the
lower explosive limit. By the time this concentration is reached, shutdown procedures or site clearance should have been put into operation.
In fact this will typically take place at a concentration of less than 50
percent of the LEL value, so that an adequate safety margin is provided.
However,
it
should
always
be
remembered
that
in enclosed
or
unventilated areas, a concentration in excess of the UEL can sometimes

occur. At times of inspection, therefore, special care needs to be taken
when operating hatches or doors, since the ingress of air from outside
can dilute the gases to a hazardous, combustible mixture.
Flammable Gas Properties Ignition Temperature:
Flammable gases also have a temperature where ignition will take place,
even without an external ignition source such as a spark or flame. This
temperature is called the Ignition Temperature. Apparatus for use in a
hazardous area must not have a surface temperature that exceeds the
ignition temperature. Apparatus is therefore marked with a maximum
surface temperature or T rating.
Toxic Gas Hazards
Some gases are poisonous and can be dangerous to life at very low
concentrations. Some toxic gases have strong smells like the distinctive
17
rotten eggs smell of H2S. The measurements most often used for the
concentration of toxic gases are parts per million (ppm) and parts per
billion (ppb). For example 1ppm would be equivalent to a room filled with
a total of 1 million balls and 1 of those balls being red. The red ball
would represent 1ppm. More people die from toxic gas exposure than
from explosions caused by the ignition of flammable gas. (It should be
noted that there is a large group of gases which are both combustible
and toxic, so that even detectors of toxic gases sometimes have to carry
hazardous area approval). The main reason for treating flammable and
toxic gases separately is that the hazards and regulations involved and
the types of sensor required are different.
Hygiene Monitoring
The term hygiene monitoring is generally used to cover the area of
industrial health monitoring associated with the exposure of employees
to hazardous conditions of gases, dust, noise etc. In other words, the aim
is to ensure that levels in the workplace are below the statutory limits.
This subject covers both area surveys (profiling of potential exposures)
and personal monitoring, where instruments are worn by a worker and
sampling is carried out as near to the breathing zone as possible. This
ensures that the measured level of contamination is truly representative
of that inhaled by the worker.
1.3.2Typical Areas that Require Gas Detection
There are many different applications for flammable, toxic and oxygen
gas detection. Industrial processes increasingly involve the use and
manufacture of highly dangerous substances, particularly toxic and
combustible gases. Inevitably, occasional escapes of gas occur, which
create a potential hazard to the industrial plant, its employees and people
18
living nearby. Worldwide incidents involving asphyxiation, explosions and

loss of life, are a constant reminder of this problem.
In most industries, one of the key parts of the safety plan for reducing
the risks to personnel and plant is the use of early warning devices such
as gas detectors. These can help to provide more time in which to take
remedial or protective action. They can also be used as part of a total
integrated monitoring and safety system for an industrial plant.
Oil & Gas
The oil and gas industry covers a large number of upstream activities
from the on and offshore exploration and production of oil and gas to its
transportation, storage and refining. The large amount of highly
flammable Hydrocarbon gases involved are a serious explosive risk and
additionally toxic gases such as Hydrogen Sulfide are often present.
Typical Applications:
Exploration Drilling Rigs
Production Platforms
Onshore oil and gas terminals
Refineries
Typical Gases:
Flammable: Hydrocarbon gases
Toxic: Hydrogen Sulfide, Carbon Monoxide
Around the boiler pipe work and burners
19
In and around turbine packages
In coal silos and conveyor belts in older coal/oil fired stations

Typical Gases:
Flammable: Natural Gas, Hydrogen
Toxic: Carbon Monoxide, SOx, NOx and Oxygen deficiency.
Waste Water Treatment Plants
Waste Water Treatment Plants are a familiar site around many cities and
towns.
Sewage naturally gives off both Methane and H2S. The rotten eggs smell
of H2S can often be noticed as the nose can detect it at less than
0.1ppm.
Digesters
Plant sumps
H2S Scrubbers
Pumps
Typical Gases:
Flammable: Methane, Solvent vapors
Toxic: Hydrogen Sulfide, Carbon Dioxide, Chlorine, Sulfur Dioxide,
Ozone.
Boiler Rooms
Boiler Rooms come in all shapes and sizes. Small buildings may have a
single boiler whereas larger buildings often have large boiler rooms
housing several large boilers.
20
Flammable gas leaks from the incoming gas main
Leaks from the boiler and surrounding gas piping
Carbon Monoxide given off badly maintained boiler

Typical Gases:
Flammable: Methane
Toxic: Carbon Monoxide
Hospitals
Hospitals may use many different flammable and toxic substances,
particularly in their laboratories. Additionally, many are very large and
have onsite utility supplies and backup power stations.
Laboratories
Refrigeration plants
Boiler rooms
Typical Gases:
Flammable: Methane, Hydrogen
Toxic: Carbon Monoxide, Chlorine, Ammonia, Ethylene oxide and
0Oxygen deficiency
Tunnels/Car Parks
Car Tunnels and enclosed Car Parks need to be monitored for the toxic
gases from exhaust fumes. Modern tunnels and car parksuse this
monitoring to control the ventilation fans. Tunnels may also need to be
monitored for the build up of natural gas.
Car tunnels
21
Underground and enclosed car parks
Access tunnels
Ventilation control
Typical Gases:
Flammable: Methane (natural gas), LPG, LNG, Petrol Vapor.
Toxic: Carbon Monoxide, Nitrogen Dioxide
Principles of Detection
Many people have probably seen a flame safety lamp at some time and
know something about its use as an early form of firedamp gas detector
in underground coal mines and sewers. Although originally intended as a
source of light, the device could also be used to estimate the level of
combustible gases- to an accuracy of about 25-50%, depending on the
users
experience,
training,
age,
colour
perception
etc.
Modern
combustible gas detectors have to be much more accurate, reliable and

repeatable than this and although various attempts were made to
overcome the safety lamps subjectiveness of measurement (by using a
flame temperature sensor for instance), it has now been almost entirely
superseded by more modern, electronic devices.
Nevertheless, todays most commonly used device, the catalytic detector,
is in some respects a modern development of the early flame safety lamp,
since it also relies for its operation on the combustion of a gas and its
conversion to carbon dioxide and water.
A further improvement in stable operation can be achieved by the use of
poison resistant sensors. These have better resistance to degradation by
substances such as silicones, sulfur and lead compounds which can
rapidly de-activate (or poison) other types of catalytic sensor.
22
To achieve the necessary requirements of design safety, the catalytic type

of sensor has to be mounted in a strong metal housing behind a flame
arrestor. This allows the gas/ air mixture to diffuse into the housing and
on to the hot sensor element, but will prevent the propagation of any
flame to the outside atmosphere. The flame arrestor slightly reduces the
speed of response of the sensor but, in most cases the electrical output
will give a reading in a matter of seconds after gas has been detected.
However, because the response curve is considerably flattened as it
approaches the final reading, the response time is often specified in
terms of the time to reach 90 percent of its final reading and is therefore
known as the T90 value. T90 values for catalytic sensors are typically
between 20 and 30 seconds.
1.3.3Gas Detection
In general, gas detection is divided into combustible gas detection and
toxic gas detection. This is a broad separation that breaks down in some
cases, e.g. some gases are both toxic and combustible in the
concentrations expected. Historically there has also been a separation in
technology between combustible and toxic detection. Below are some of
the issues you need to consider when choosing gas detectors. Most
devices used in the oil and gas industry are set to detect methane ( CH 4) or
hydrogen sulphide (H2S). Many detectors show cross-sensitivity; i.e. a
detector for detecting one gas will also detect another, at different
readings. So at the time of purchase it is important to specify the gas
that is to be detected and consider other gases that may be present that
may affect the readings. The nature of the gas should be considered
e.g. H2S is heavier than air, methane rises, propane sinks. However they
may not behave like that under a high pressure discharge. Altitude
23
affects the readings of some detectors. Portable personal gas detectors,

set for multiple gasses may be used in areas where toxic gases may be
present.
Combustible Gas Detection
Two mainstream technologies are available infra-red absorption and
catalytic types. Other types are available and in development; e.g. metal
oxide semiconductor sensors. Detection methods from the field of
analyzers may cross over to meet gas detection needs.
Point detectors are calibrated against the lower explosive limit (LEL) of a
certain gas, frequently methane. The lower explosive limit for methane
mixed in air is achieved at a 5% concentration. Typical alarm settings are
20% LEL and 60% LEL. Confusion can arise as these levels are
traditionally labelled low gas and high gas, whereas control instrument
engineers would use the term high alarm and high-high alarm.
Open path gas detectors are calibrated in LEL metres (LELm). This
setting has evolved as an analogue with the LEL range used in point
detectors.
Infra-red Absorption Combustible Gas Detection
The technology uses the absorption characteristics of the hydrocarbon
molecules to infra-red light. The more hydrocarbon molecules are
present, the higher the absorption of infra-red radiation. More than one
type of hydrocarbon gas may be detected.
This technology is more expensive than catalytic detection, but it is used
for many applications as it doesnt need field calibration and proof test
intervals are considerably better (longer) than for catalytic types. Speed
of response is quicker than for catalytic types. The measured value
24
doesnt drift unlike catalytic detectors. And unlike catalytic types, the
detector doesnt need oxygen for operation,
Point infra-red gas detectors
Point detectors record the gas concentration at the detector location.
They need to be placed where a release of gas is considered possible.
They can be placed remotely and connected to the sampling location by
tubes, with air sucked across the detecting chamber. Consideration
needs to be given to the extra detection time added by the transit time
down the tube.
Example uses: Detection in confined spaces, specific locations, air inlets
etc.
Open path infra-red gas detectors

Open path gas detectors have a separate transmitter and receiver.
Manufacturers quote up to 200m range, but in practice smaller distances
are used, due to climatic and practical mounting arrangements.
Detectors should be mounted rigidly to avoid misalignment between the
transmitter and receiver, both statically and due to vibrations. Current
devices will detect more than one hydrocarbon gas. New devices are in
development that are tuned to a particular gas. Different versions of
these can also detect H2S.
Example uses: Migration detection, pipe rack monitoring.
Catalytic Gas Detectors
25
Catalytic detectors rely upon burning gas in a sintered chamber. For this
reason they are only available as a point detector or as part of a multipoint aspirating system.
Various technologies are available chemical cell and semiconductor
point detectors; open path (Laser) gas detection is in development.
Many different types of gas can be detected. Cross-sensitivity to different
gases other than those being looked for needs to be given careful
attention.
Response times of detecting and testing frequencies need careful
attention.
Chemical cell types require sensor replacement at intervals determined
by the environment. Semiconductor cells are also affected by their
environment and may need to be kept awake by exposure to the detected
gas. New products are in development that are less susceptible to these
limitations.
Infra-red single gas open path detectors are at an advanced stage of
development. These offer the important advantages of fast response and
high reliability.
Example uses: H2S from sour oil wells or processing plant; carbon
monoxide from burning products and Co2 (Carbon Dioxide) build up
Calibration
The most common failure in catalytic sensors is performance degradation
caused by exposure to certain poisons. It is therefore essential that any
gas monitoring system should not only be calibrated at the time of
installation, but also checked regularly and re-calibrated as necessary.
Checks must be made using an accurately calibrated standard gas
26
mixture so that the zero and span levels can be set correctly on the
controller.
Codes of practice such as EN50073:1999 can provide some guidance
about the calibration checking frequency and the alarm level settings.
Typically, checks should initially be made at weekly intervals but the
periods can be extended as operational experience is gained. Where two
alarm levels are required, these are normally set at 20-25% LEL for the
lower level and 50-55% LEL for the upper level.
Today, there are a number of one-man calibration systems available
which allow the calibration procedures to be carried out at the sensor
itself. This considerably reduces the time and cost of maintenance,
particularly where the sensors are in difficult to get to locations, such as
an off-shore oil or gas platform. Alternatively, there are now some
sensors available which are designed to intrinsically safe standards, and
with these it is possible to calibrate the sensors at a convenient place
away from the site (in a maintenance depot for instance). Because they
are intrinsically safe, it is allowed to freely exchange them with the
sensors needing replacement on site, without first shutting down the
system for safety.
Maintenance can therefore be carried out on a hot system and is very
much faster and cheaper than early, conventional systems.
1.3.4 Location of Sensors
How many detectors do I need? and where should I locate them? are
two of the most often asked questions about gas detection systems, and
probably two of the most difficult to answer. Unlike other types of safety
related detectors, such as smoke detectors, the location and quantity of
detectors required in different applications is not clearly defined.
27
The placement of detectors should be determined following the advice of

experts having specialist knowledge of gas dispersion, experts having
knowledge of the process plant system and equipment involved, safety
and engineering personnel. The agreement reached on the location of
detectors should also be recorded.
Detectors should be mounted where the gas is most likely to be present.
Locations requiring the most protection in an industrial plant would be
around gas boilers, compressors, pressurized storage tanks, cylinders or
pipelines. Areas where leaks are most likely to occur are valves, gauges,
flanges, T-joints, filling or draining connections etc.
There are a number of simple and quite often obvious considerations that
help to determine detector location:
To detect gases that are lighter than air (e.g. Methane and Ammonia),
detectors should be mounted at high level and preferably use a collecting
cone. To detect heavier than air gases (e.g. Butane and Sulfur Dioxide),
detectors should be mounted at a low level. Consider how escaping gas
may behave due to natural or forced air currents. Mount detectors in
ventilation ducts if appropriate. When locating detectors consider the
possible damage caused by natural events e.g. rain or flooding. For
detectors mounted outdoors it is preferable to use the weather protection
assembly. Use a detector sunshade if locating a detector in a hot climate
and in direct sun. Consider the process conditions. Butane and
Ammonia, for instance are normally heavier than air, but if released from
a process line that is at an elevated temperature and/or under pressure,
the gas may rise rather than fall. Detectors should be positioned a little
way back from high pressure parts to allow gas clouds to form.
Otherwise any leak of gas is likely to pass by in a high speed jet and not
28
be detected. Consider ease of access for functional testing and servicing.

Detectors should be installed at the designated location with the detector
pointing downwards. This ensures that dust or water will not collect on
the front of the sensor and stop the gas entering the detector. When
siting open path infrared devices it is important to ensure that there is
no permanent obscuration or blocking of the IR beam. Short term
blockage from vehicles, site personnel, birds etc can be accommodated.
Ensure the structures that open path devices are mounted to are sturdy
and not susceptible to vibration.
1.4Control Systems and mitigation
Mitigating actions
Actions may range from alerting a control room operator, release of
extinguishants to a complete plant shut down to sounding an evacuation
alarm. The control room operator may be part of the control loop perhaps
by being required to decide whether to initiate a general alarm or plant
shut-down.the ozone depleting effects of Halon 1301 and its almost
complete ban has led to a review of the general use of automatically
released exinguishants and an increase in emphasis on early warning of
fire and manual interventions. This emphasis is, however, company and
country specific.
Start water fire pumps
Frequently fire pumps are started as a precautionary measurement
detection of fire or on a manually initiated fire indication. Fire pumps can
normally or stopped locally to the fire pump. Fire pump control logicsequencing is sometimes performed by a fire and gas system. It can also
29
be implemented in dedicated fire pump controllers supplied by a fire

pump supplier.
A manual start fire pump push-button should be provided in the control
room wired directly to the fire pump control panel.
Initiate Plant Alarms
Plant alarms can be automatic or manual and can be wired directly the
fire and the gas system or form part of a general, high integrity public
address system.
Consideration should be given to an alarm hierarchy and local zoning.
For example is it necessary to evacuate a complete site based local alarm
in an instrument room? visual repeats of audible alarms may be needed
in noisy areas. Some jurisdictions require all audible alarms to be
accompanied by a visual indication such as an integrated flashing.
beacon(srobe) . Colours of visual indications need to be established at an
early stage to ensure that they dont clash with other indicators . The
chopice of colours affects the distance covered by a device of given power.
30
Fig 5: Horn & Beacon

For audible alarms, consideration needs to be given to how many
different sounds are required and how many sounds the plant personnel
can distinguish. Voice messages offer greater flexibility in conveying
messages, but may not be so effective in multilingual projects or
comprehensible to off-site personnel.
If alarm signaling is via another system, it needs to be established which
system has control over facilities such as system resetting, inhibiting and
silencing.
Choice of interface could be hard wired, secure serial or a combination
using remote I/O (inputs and outputs) co-located at the alarm signaling
system.
Audible and visual alarms can be initiated in the following ways:
Automatically on detection of fire, perhaps requiring more than one fire
detector to operate(voting) automatically on detection of gas, perhaps
voted automatically after a delay to allow for manual
intervention
manually by the control room operator manually by manual call point in

the field other combinations of the above
31
1.4.1Fire alarm control panel
A Siemens MXL fire alarm control panel (top) and graphic annunciator.
A Fire Alarm Control Panel (FACP), or Fire Alarm Control Unit (FACU),
is the controlling component of a Fire Alarm System. The panel receives
information from environmental sensors designed to detect changes
associated with fire, monitors their operational integrity and provides for
automatic control of equipment, and transmission of information
necessary to prepare the facility for fire based on a predetermined
sequence. The panel may also supply electrical energy to operate any
associated sensor, control, transmitter, or relay. There are four basic
32
types of panels: coded panels, conventional panels, addressable panels,

and multiplex systems.
Conventional Fire Alarm Control Panels
Conventional panels have been around ever since electronics became
small enough to make them viable. conventional panels are used less
frequently in large buildings than in the past, but are not uncommon on
smaller projects such as small schools, stores, restaurants, and
apartments.
A conventional Fire Alarm Control Panel employs one or more circuits,
connected to sensors (initiating devices) wired in parallel. These sensors
are devised to dramatically decrease the circuit resistance when the
environmental influence on any sensor exceeds a predetermined
threshold. In a conventional fire alarm system, the information density is
limited to the number of such circuits used.
To facilitate location and control of fire within a building, the structure is
subdivided into definite areas or zones. Floors of a multistory building
are one type of zone boundary.
An Initiating Device Circuit connected to multiple devices within the
same "zone" of protection, effectively provides 2 bits of information about
the zone corollary to the state of the circuit; normal, or off normal and
alarm or quiescent. The state of each Initiating Device Circuit within a
zone displays at the Fire Alarm Control Panel using visible indications
called Annunciators.
These Annunciators may employ a graphical representation of the Zone
boundaries on a floor plan (Zone map) using textual descriptions,
illuminated icons, illuminated sections, or illuminated points on the map
33
corresponding to Initiating Circuits connected to the Fire Alarm Control

Panel.
For this reason, slang often inaccurately refers to initiating circuits of a
Fire Alarm Control Panel as Zones.
Larger systems and increasing demand for finer diagnostic detail beyond
broad area location and control functions expanded the control by Zone
strategy of conventional systems by providing multiple initiating circuits
within a common Zone, each exclusively connected to a particular type of
initiating device, or group of devices. This arrangement forms a device
type by Zone matrix whose information is particularly suited to
the Tabular Annunciator In multistory buildings employing a Tabular
Annunciator for Example; rows of indicators define the floors horizontally
in their stacked relationship and the type of device installed on that floor
displays as columns of indicators vertically aligned through each floor.
The intersection of the floor and device indicators provides the combined
information. The density of information however remains a function of
the number of circuits employed.
Even larger systems and demands for finer diagnostic and location detail
led to the introduction of addressable fire alarm systems with each
addressable device providing specific information about its state while
sharing a common communication circuit. Annunciation and location
strategies for the most part remain relatively unchanged.
34
Fig: 6 Wiring Diagram

A wiring diagram for a simple fire alarm system consisting of two input
loops (one closed, one open)
Releasing panels
Releasing panels are capable of usings solenoids to disperse fire-fighting
chemical agents such as halon or water from piping located throughout a
building. A releasing panel usually will have a manual abort switch to
abort an accidental release which could damage property or equipment.
Releasing capability can be part of both addressable or conventional
panels.
Addressable Fire Alarm Control Panels
35
Fig 7: Addressable FACP
A Simplex 4100U InfoALARM addressable fire alarm control panel: note

the voice-evacuation microphone built into it
Signaling Line Circuits
Addressable Fire Alarm Control Panels employ one or more Signaling
Line Circuits, slang - usually referred to as loops or SLC loops - ranging
between one and thirty. Depending on the protocol used, a Signaling Line
Circuit can monitor and control several hundred devices. Some protocols
permit any mix of detectors and input/output modules, while other
protocols have 50% of channel capacity restricted to detectors/sensors
and 50% restricted to input/output modules. Each SLC polls the devices
connected, which can number from a few devices to several hundred,
depending on the manufacturer. Large systems may have multiple
Signaling Line Circuits.
[1] [2]
Each device on a SLC has its own address, and so the panel knows the
state of each individual device connected to it. Common addressable
input (initiating) devices include
36
Smoke detectors
Heat Detectors (Rate of Rise and Fixed Temperature)
Manual call points or manual pull stations
Notification appliances (Simplex systems with TrueAlert signals

only)
Responders
Fire sprinkler system inputs
Switches
Flow control
Pressure
Isolate
Standard switches
Addressable output devices are known as relays and include
(Warning System/Bell) Relays
Door Holder Relays
Auxiliary (Control Function) Relays
Relays are used to control a variety of functions such as
Switching fans on or off
Closing/opening doors
Activating fire suppression systems
Activating notification appliances
Shutting down industrial equipment
Recalling elevators to a safe exit floor
Activating another fire alarm panel or communicator
Mapping
Also known as "cause and effect" or "programming", mapping is

the process of activating outputs depending on which inputs have
37
been activated. Traditionally, when an input device is activated, a

certain output device (or relay) is activated. As time has
progressed, more and more advanced techniques have become
available, often with large variations in style between different
companies.
Zones
Zones are usually made by dividing a building, or area into

different sections. Then depending on the specific zone, a certain
amount and type of device is added to the zone to perform its given
job.
Groups
Groups contain multiple output devices such as relays. This allows

a single input, such as a smoke detector or MCP, to have only one
output programmed to a group, which then maps to between two
to many outputs or relays. This enables an installer to simplify
programming by having many inputs map to the same outputs,
and be able to change them all at once, and also allows mapping to
more
outputs
than
the
programming
space
for
single
detector/input allows.
Boolean logic
This is the part of a fire panel that has the largest variation
between different panels. It allows a panel to be programmed to
implement fairly complex inputs. For instance, a panel could be
programmed to notify the fire department only if more than one
device has activated. It can also be used for staged evacuation
procedures in conjunction with timers.
38
Networking
The principle of networking involves connecting several panels

together to form a system. Inputs on one panel may activate
outputs on another, for example, or the network may allow
monitoring of many systems. Networking is often used in situations
where one panel is not large enough, or in multiple-building
situations. These are often done with manufacturers' "top of the
line" control panels.
Although quasi-standards exist that allow panels from different

manufacturers to be networked with each other, they are not in
favor with a lot of companies. One of the most common protocols
used BAC net which is used for various type of industrial networks.
More
recently,
some
panels
are
being
networked
with
standard Ethernet, but this is not yet very common. Most

organizations choose to create their own proprietary protocol,
which has the added benefit of allowing them to do anything they
like, allowing the technology to progress further. However, a
bridging layer between the proprietary network and BACnet is
usually available]
Networking may be used to allow a number of different panels to be

monitored by one graphical monitoring system.
Monitoring
In nearly every state in the USA, the International Building

Code requires fire alarm and sprinkler systems to be monitored by
an approved supervising station.
39
A fire alarm system consists of a computer-based control connected

to a central station. The majority of fire alarm systems installed in
the USA are monitored by a UL listed or FM Global approved
supervising station.
These systems will generally have a top level map of the entire site,
with various building levels displayed. The user (most likely a
security guard) can progress through the different stages. From
top level site building plan floor plan zone plan, or however
else the building's security system is organised.
A lot of these systems have touch screens, but most users tend to
prefer a mouse (and a normal monitor), as it is quite easy for a
touch screen to become misaligned and for mistakes to be made.
With the advent of the optical mouse, this is now a very viable
option.
System functions
Fig 8: System Functions
There are many functions on a fire alarm panel. Some of these are:
40
System reset
This resets the panel after an alarm condition. All initiating devices are
reset, and the panel is cleared of any alarm conditions. If an initiating
device is still in alarm after the system is reset, such as a smoke
detector continuing to sense smoke, or a manual pull station still in an
activated position, another alarm will be initiated. A system reset is often
required to clear supervisory conditions. A system reset does not usually
clear trouble conditions. Most trouble conditions will clear automatically
when conditions are returned to normal.
On UK and most US panels, a "Silence" or "Acknowledge" is usually
required before a "System Reset" can be performed.
Acknowledge
This function, also abbreviated to "ACK", is used to acknowledge an
abnormal situation such as an alarm, trouble or supervisory. The
acknowledge function tells the panel that building personnel or
emergency responders are aware of the alarm, trouble, or supervisory
condition. Acknowledging the alarm or trouble condition also normally
silences the panel's own sounder, but does not silence any Notification
Appliances.
41
Fig 9: Fire alarm panel, showing drill switch
Drill
Also known as "manual evacuation" or "evacuate". On panels that have
this function, the drill function activates the system's notification
appliances, often for purposes of conducting a fire drill. Using the drill
function, an alarm is normally not transmitted to the fire department or
monitoring center. However, building personnel often notify these
agencies in advance in case an alarm is inadvertently transmitted.
Walk test
Walk test allows the functional testing of the system's devices without the
assistance of additional people at the control panel itself. It is also
designed to allow initiating devices to be tested without setting off the
building's alarms. Most panels offer the option for a silent walk test (no
alarms activate) or an audible walk test (alarms activate for a brief period
42
when a device is initiated). A system trouble is typically generated while

the panel is in walk test mode. On European panels, this is usually an
engineer-only function and cannot be activated by a user.
Signal silence
Also known as "alarm silence" or "audible silence". Depending on the
configuration of the alarm system, this function will either silence the
system's notification appliances completely, or will silence only the
audible alarm, with strobe lights continuing to flash. Audible silence
allows for easier communication amongst emergency responders while
responding to an alarm. This can also be used during construction as a
means of a preliminary test, before the final full test.
Lamp test
Also known as "flash test". This button is known to have become
obsolete, but is still used on many panels. This function is used to check
the condition of the LEDs themselves. A "Lamp Test" button is required
by code on multi-zone panels installed in Canada. Many panels do a
lamp test when the system is reset.
Alarm circuit supervision
Various forms of alarm circuit supervision have been used to indicate
trouble with an alarm circuit. Possible alarm circuit faults on a two wire
circuit include one of the conductors being shorted to ground, open
circuit (conductor continuity break), or a short circuit between the
conductors. Also the circuits could be tampered with by having an
external AC or DC voltage applied with various duty cycles or waveforms.
There are a number of US patents that address this issue and some have
been implemented in available system products. One of the first to
43
address this issue was Patent No. 3,588,890 "Resistance Sensing

Supervisory System" issued on June 28, 1971 and assigned to General
Motors Corporation. General Motors used this supervision on all circuits
installed in GM plants starting in 1970. [3] An improvement to this basic
"Resistance Sensing Supervisory System" can be obtained by providing a
pulsed or time dependent variable voltage applied to the alarm circuit
and is addressed in US patent numbers 4,030,095 [1] and 4,716,401 [2].
Panel alerting
Many panels today have the capability of alerting building personnel of a
situation which can arise into a potentially serious problem. Fire alarm
panels indicate an abnormal condition via a solid or flashing LED. Some
panels also contain a small sounder, used in conjunction with the visual
alert. A number of indicators are shown below. Note that not all fire
alarm panels have all of these indicators.
Alarm
Also known as "Fire" or "General Alarm". This indicator is lit when an
alarm condition exists in the system, initiated by smoke detectors, heat
detectors, sprinkler flow switches, manual pull stations, manual call
points, or otherwise. Along with the indicator on the panel, notification
appliances, such as horns and strobes, are also activated, signaling a
need to evacuate to building occupants. In an alarm condition, the fire
alarm panel indicates where the alarm originated. The alarm panel can
be reset once the device which initiated the alarm is reset, such as
returning the handle of a manual pull station to its normal position.
Audible silence
44
The Audible Silence indicator is used in conjunction with the "Alarm"

indicator. It indicates that the fire alarm panel is still in an alarm
condition, but that notification appliances have been silenced. While the
alarm is silenced, other functions in an alarm condition continue to
operate, such as emergency service for elevators, stairway pressurization,
and ventilation functions. A new alarm initiation while the alarm is
silenced will take the panel out of Audible Silence and reactivate the
notification appliances.
Report
Also known as "Brigade Called". This indicator is activated when
emergency responders have been automatically notified by the fire alarm
system. A variant of this LED known as "kissoff" activates when the
monitoring center replies back to the panel, indicating a successful
communication. Requirements vary depending on jurisdiction regarding
whether a direct connection to the fire department is required, optional,
or prohibited. If a connection to the fire department is optional, or is
prohibited, a fire alarm system is often connected to a monitoring center
at the building owner's discretion.
Drill
Also known as "Manual Evacuation" or "Evacuate". On panels containing
this function, the "Drill" indicator shows that the alarm condition was
activated from the fire alarm panel, often in order to conduct a fire drill.
When an alarm is initiated for a drill, the fire department or monitoring
company is usually not notified automatically. However, building
personnel preparing to conduct a fire drill often will provide advance
notice of a drill to the fire department and monitoring center in case an
alarm is unintentionally transmitted.
45
Pre alarm
This LED is often used in conjunction with a two-stage system, in which
the panel requires two devices to be activated (and/or a predetermined
time limit to run out after one device is activated) in order to go into full
alarm.[4] This is mostly used in areas where false alarms are a common
problem, or in large applications (such as hospitals) where evacuating
the entire building would not be efficient. The prealarm LED is lit when
one device has tripped. The prealarm LED may also be used if an analog
smoke detector registers low levels of smoke in the detection chamber,
but not enough to trigger a full alarm. [5] Depending on the system's
layout, the NAC's may or may not activate for prealarm conditions. In a
two-stage system, the NAC's are typically coded to a special first-stage
coding, or in some situations where a loud alarm signal could be
disruptive, chimes will activate. If there is a voice evacuation system, it
will usually instruct building occupants to await further instructions
while the alarm is being investigated.
Priority 2 alarm
Also known as "Security". This LED is common on top-of-the-line
intelligent panels. This LED can only activate if there is a secondary
device hooked into the "Priority 2 Alarm" terminals. This secondary
device could be a security system, building management system, or
another fire alarm control panel. Depending on how the panel is
programmed, the panel's alarms may or may not activate when a
condition like this is present.
Trouble
46
Also known as "Fault" or "Defect". When held steady or flashing, it means

that a trouble condition exists on the panel. Trouble conditions are often
activated by a contaminated smoke detector or an electrical problem
within the system. Trouble conditions are also activated by a zone being
disabled (disconnected from the system), a circuit being disabled, low
power on the backup battery, the disabling of a notification appliance,
the ground faults, or short or open circuits. Usually the alarm panel's
sounder will activate if a trouble condition exists, though older systems
would sometimes activate a bell or other audible signal connected to the
panel. In a trouble condition, the panel displays the zone or devices
causing the condition. Usually, the "Trouble" indicator goes out
automatically when the situation causing the trouble condition is
rectified, however in some systems (EST) the panel must be reset to clear
the trouble alarm. Some panels have more specific indicators such as
'Trouble-PSU' which shows when the panel itself is compromised and
'Trouble-Bell' ('Sounder fault' on UK panels) which shows that the
sounders are not functioning correctly. On most panels, an acknowledge
button is pressed to turn off the panel's buzzer.
Supervisory
This signal indicates that a portion of the building's fire protection
system has been disabled (such as a fire sprinkler control valve being
closed and, consequently, a sprinkler tamper switch being activated), or,
less frequently, that a lower priority initiating device has been triggered
(such as a duct smoke detector). Depending on the system's design, the
supervisory point may be latching, meaning the panel must be reset to
clear the supervisory condition, or non-latching, meaning the indicator
automatically goes out when the condition has cleared. However, some
47
panels require a reset regardless of whether the supervisory point is

latching or non-latching.
AC power
Also known as "Normal". When this indicator is lit, power is being
provided to the system from the building's electrical system, and not from
the backup battery. When an AC power condition changes, the Trouble
indicator comes on and the AC power indicator goes off and the screen
alerts building personnel of a power failure. If the AC power indicator is
lit without any other indicators also lit, then the system is in a normal
condition. If no LEDs are lit, there is no power source feeding the panel.
DC power
This is used to tell the operator that DC power (batteries) are being
charged or used. While using DC power, the system remains in a trouble
condition.
Highrate
This LED is on when there are unusual power-line conditions.
1.5Programmable Logic Controller (PLC)

Programmable logic control or PLC is the most commonly used
industrial automation technique in the world. It is universally
applied
for
factory
automation,
process
control
and
manufacturing systems. Programmable logic control originated

from the creation of computerized versions of relay control
systems used to control manufacturing and chemical process
systems. The programming is done using a special technique
called ladder logic, which allows sequences of logical actions to be
48
set up, inter-linked and timed. A standard task in logic control is

batch control and sequencing in a process system.
1.5.1 PLC Introduction
A PLC or Programmable Logic Controller is a user friendly,
microprocessor specialized computer that carries out control
functions of many types and levels of complexity. Its purpose is to
monitor
crucial
process
parameters
and
adjust
process
operations accordingly. It can be programmed, controlled and

operated
by
person
unskilled
in
operating
computers.
Essentially, a PLC's operator draws the lines and devices of ladder

diagrams with a keyboard onto a display screen. The resulting
drawing is converted into computer machine language and run as
a user program.
PLC will operate any system that has output devices that go on
and off (Discrete, or Digital, outputs). It can also operate any
system with variable (analog) outputs. The Programmable Logic
Control can be operated on the input side by ON/OFF devices or
by variable (analog) input devices.
Control engineering has evolved over time. In the past humans
was the main method for controlling a system. More recently
electricity has been used for control and early electrical control
was based on relays. These relays allow power to be switched on
and off without a mechanical switch. It is common to use relays
to make simple logical control decisions. The development of low
cost computer has brought the most recent revolution, the
Programmable Logic Controller (PLC). The advent of the PLC
49
began in the 1970s, and has become the most common choice for
manufacturing controls.
Programmable Logic Controllers have been gaining popularity on
the factory floor and will probably remain predominant for some
time to come. Most of this is because of the advantages they offer.
1.5.2 PLC Advantages and Disadvantages
Flexibility: One single Programmable Logic Controller can easily

run many machines.
Correcting Errors: In old days, with wired relay-type panels, any

program alterations required time for rewiring of panels and
devices. With PLC control any change in circuit design or sequence
is as simple as retyping the logic. Correcting errors in PLC is
extremely short and cost effective.
Space Efficient: Today's Programmable Logic Control memory is

getting bigger and bigger this means that we can generate more
and more contacts, coils, timers, sequencers, counters and so on.
We can have thousands of contact timers and counters in a single
PLC. Imagine what it would be like to have so many things in one
panel.
Low Cost: Prices of Programmable Logic Controlers vary from few

hundreds to few thousands. This is nothing compared to the prices
of the contact and coils and timers that you would pay to match
the same things. Add to that the installation cost, the shipping
cost and so on.
50
Testing: A Programmable Logic Control program can be tested and

evaluated in a lab. The program can be tested, validated and
corrected saving very valuable time.
Visual observation: When running a PLC program a visual

operation can be seen on the screen. Hence troubleshooting a
circuit is really quick, easy and simple.
1.5.3 ALLEN BRADLEY PLC MICROLOGIX 1200 CONTROLLER.

AB PLC TYPES:
Allen Bradley PLCs, the standard by which other PLCs are measured.
From the very inception of the idea of the programmable logic controller
the Allen Bradley PLC's were there. Thirty years of history and
experience is involved in every Allen Bradley programmable logic
controller that you get, helping you to move forward, to exert powerful
and expert control of your devices. .
The Programmable logic controller was designed to provide you with the
control solutions that you need for your remote mechanics. The Allen
Bradley controllers offer some key ways to solve your problems and to
give you what you need.
Solving the challenges of manufacturing and lowering your costs is the
business of every business. Improving your output, increasing the quality
and the flexibility that you have is your secondary aim. Allen Bradley
programmable logic controllers are expert at those things. They bring to
your business a highly customizable integrated solution to the control of
your systems and devices. Your PLC will be up the challenges that you
face when you select the Allen Bradley Programmable logic controller.
51
The Allen Bradley Programmable logic controllers help you in both time
and money saving, as well as offering you a faster start-up. Your new fast
start up time is a result of products that are pre-integrated--designed to
fit together like pieces of a well oiled puzzle. From the beginning to the
end of the operation, the maintenance will be far less and the need for
programming will be minimal.
Allen
Bradley
is
part
of
Rockwell
Automation
Integrated
Architecture and offers controllers that are suitable for drives, for
motion, and for process controlling. No matter what you need, if you have
to have high performance or value based in your programmable logic
controller system, you will find just the right controller with the Allen
Bradley programmable logic controllers.
The many different offerings from Allen Bradley-Rockwell Automation
Integration include the NetLinx, the Kinetix, and the Logix. All of these
will offer you maximum capabilities, easy use, reuse capacity of program,
flexibility in the communications system and fast easy use so that you
can spend less of your company's time and money on the entire setup
process.
Allen Bradley uses five different types of programmable logic controllers.
These different types of PLCs perform specialized functions.
Pico Controllers are simple, as well as flexible and small, performing
logic, counting, time and clock operations..
MicroLogix PLCs are a cost-effective solution for micro-control that will
expand as needed.
SLC 500s are small, modular programmable controllers that are chassisbased. It is often the choice for I/O and power supply functions.
52
PLC-5 is the most popular Allen Bradley PLC and can be found
worldwide, providing flexibility in networking, I/O and programming and
being suitable for a wide variety of applications. .
1758-RTU is a programmable logic controller designed for rugged and
harsh environments as a Remote Terminal Unit (RTU).
From conception to implementation, any Allen Bradley programmable
logic controller results in cost savings, increased productivity and
satisfied clients.
System Overview
53
The MicroLogix 1200/1762 system provides functionality between the MicroLogix

1000/1761 and MicroLogix 1500/1764 systems, using the proven MicroLogix and
SLC family architecture. The 6K-word memory provides for a maximum program
of 4K words and maximum data of 2K words with 100% data retention. An optional
memory module provides program and data backup with program upload and
download capability. The optional real-time clock enables time scheduling of control
activities. The flash upgradeable operating system lets you upgrade system software
without replacing hardware.
Product Design
The MicroLogix 1200 controller and expansion I/O modules provide a modular,
rackless control system designed for ease of installation and maintenance. Each
MicroLogix 1200 controller includes a processor, built-in I/O, and power supply.
Expansion I/O modules install to the right of the controller. Cables built into the
I/O modules provide connection to the adjacent I/O module or controller.
Controllers and I/O modules can be mounted either on a panel or on a DIN-rail.

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1

(Programmable Logic Controller):

opportunities for the betterment of students has been inspiring to us to

has been helpful

throughout. We owe our deepest gratitude to our faculty adviser

programmable memory for the internal storage of user-orientated

sequencing, timing, counting, & arithmetic to control, through digital or

1.2 Introduction to Smoke Detector

1.2.1 Conventional type

1.2.2 Addressable type

1.3.1 Gas hazarda

1.3.2 Typical areas that require gas detection

1.3.3 Gas detection

1.3.4 Location of Sensors

1.4 Control systems and Mitigation

1.4.1 Fire alarm Control Panels

1.5 PLC(PROGRAMMABLE LOGIC CONTROLLER)

1.5.1 Introduction to PLC

1.5.2 PLC Advantages and Disadvantage

1.5.3 Allen Bradley PLC Micrologic 1200 Controller

CHAPTER 2: HARDWARE DESCRIPTION

2.1 Block Diagram

2.2 Wiring Diagram

2.3 Smoke Sensor

2.3.1 Product Introduction

2.3.2 Product profile

2.4 Gas Detector

2.4.3 Gases Detected

2.5 Pump, Solenoid Valve, Fan, Relays

CHAPTER 3: PLC PROGRAMMING

3.3 Ladder Logic Structure

3.4 Ladder Logic Programming Basic Instructions

CHAPTER 4:LOGIC DEVELOPMENT

4.1 Electrical circuit-Logic diagram relationship

4.3 Ladder Diagram Symbols

4.4 Developing a ladder diagram

4.5 Automatic Mode of Operation

4.6 Ladder Diagram Analysis

4.7 Developing the PLC Program Logic

4.8 Power Supply Section

4.9.1Full Wave Rectifier

4.9.2 Full Wave Bridge Rectifier

CHAPTER 5: PROJECT PICTORIAL

Full Wave Rectifier Circuit

Fig 44: Programming Sreen Shot-2

Fig 45: Programming Screen Shot-3

Fig 46: Programming Screen Shot-4

Fig 47: Programming Screen Shot-5

A Smoke detector was installed on a chamber, when it senses the smoke;

1.2 Introduction to Smoke Detector

deter, smoking in areas where it is banned such as toilets and schools.

detectors in large commercial,

industrial, and residential

buildings are usually powered by a central fire alarm system, which is

Fig1: Inside view of Smoke Detector

Inside a basic ionization smoke detector. The black, round structure at

element americium-241 (241Am), corresponding to about 0.3 g of the

Typical smoke detector obscuration ratings[9]

2.65.0% obs/m (0.81.5% obs/ft)

6.513.0% obs/m (24% obs/ft)

3% obs/m (0.9% obs/ft)[citation needed]

0.00520.5% obs/m (0.00156.25% obs/ft)

0.066.41% obs/m (0.022.0% obs/ft)[10]

Smoke&Gas With PLC Project1-Modified

Smoke&Gas With PLC Project1-Modified