BUSCS Development using AUTOMGEN and PLC Ladder Support Software

This project of "BUSCS Development using AUTOMGEN and PLC Ladder
Support Software" is basically controlling a simplified process based on an actual
production line of Bulk Urea Storage Control System (BUSCS) of Asean Bintulu
Fertilizer Sdn. Bhd. using Programmable Logic Controller (PLC) and
AUTOMGEN7 software. In this project, the student has developed a hardware
system using PLC as the main controller and AUTOMGEN7 software which is used
to control as well as monitor the operation ofthe whole system.
The designing comprises three major elements that need to be developed. First, to
develop PLC program using ladder diagrams as the main controller. Then,
developing the hardware system using the input and output devices required in
controlling the whole process. Lastly, to develop the Human Machine Interface
(HMI) using AUTOMGEN7 to simulate the whole operation ofthe system.
The hardware system is based on the actual production line of Bulk Urea Storage
Extension Project ofASEAN Bintulu Fertilizer Sdn. Bhd. Therefore, the initial stage
of the project has been focused on studying the production line and also produces
the complete sequence of operations. This is a crucial phase of the project since the
student need to have detailed understanding of the complete operation and the
control logic ofthe BUSCS.
The main objective for this project is to compare the existing system of using relay
logics with the use of Programmable Logic Controller (PLC) system in controlling
industrial processes. Both systems have been compared in terms of advantages and
disadvantages and also in terms of system configuration and complexity.
Based on this study, it has been found that PLC is a viable method in controlling an
industrial process due to its reliability and maintainability. Supported by industrial
standard software like AUTOMGEN7 and other PLC support components, the future
ofPLC in industrial control is borderless.