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INTRODUCTION

A production company has requested for the design of a process plant for the production of juice. It is

mearnt to consist of 5 tanks, in which, tank 1, 2 and 3 holds raw materials worth a capacity of 5000

gallons, tank 3 is mixing tank that holds a capacity of 500 to 800kg and tank 5 is the storage tank. As the

objective is meant to blend a product, a manufacturing process from tank 1 to tank 5 will be explained

throughout this report about how the products get mixed up, the sensors and theinstruments being

used to make the operation a success.

OBJECTIVE

The concept of making orange juice

Analyzing the sensors and instruments used

Understanding the manufacturing process

PROCEDURES ( all tanks must have manual valve)

Tank 1

The raw material in this tank is the water. Being in a container having 5000 gallons maximum storage,

the tank contains 1 water inlet and 2 outlets. The water inlet defines the water entry which is meant to

fill up the tank when the water level has gone below the required limit. It contains am automated valve

in order to allow or block the water entry when the level reaches its limit, and a magnetic level gauge for

manual check up. The tank contains two outlets whereby one serves as passage to the mixer and one

 just in case there is an error in the system which gives an exit until the inlet is closed with a manual

valve. A level sensor is placed above the tank to detect the water level. When the mixer requests for a

certain amount of water, it sends the signal to the main controller, which in turn requests the tank 1

controller to release the required amount by opening the valve; a flow measurement sensor is placed at

the opening of the valve to ensure the amount is not exceeded and sends a signal to the tank 1

controller to close the valve automatically when its limit is reached. The water being pumped by a pump

valve flows through a heater having a temperature sensor to ensure that the water is heated to about

80-85°Celsius which then flows straight to the tank 4 (mixer). ( as a precuation all the inlets and outlets

are fitted with manual valves that can be used by an operator to shut down the process incase of an

emergency, or sytem andd sensor failure). 

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Tank 2

The raw material in this tank is the sugar. It contains an entry to allow the sugar inlet in case the level

has decreased below the required limit. It has a weight sensor at the bottom of the tank to ensure of the

change in weight in the tank during release. The tank 2 is actually placed at some distance above the

mixer to easily allow the flow of sugar. When the mixer requests for an amount of sugar, it sends the

signal to the main controller which on its turn sends a request to the tank 2 controller to release the

required amount. The controller signals the valve to open; there is actually a vacuum pump that

aspirates the sugar to give it more pressure all the way to the mixer. The weight sensor actually

determines the level of the sugar in the tank, but once it is being emptied it calculates the amount of 

sugar being released by its weight-age until the required amount assigned by the mixer is reached.

Therefore, it sends a signal to the controller to close the valve, and the released sugar goes straight to

the mixer. ( also fitted with a manual valve at its exit as a precaution incase of system failure a operater

can shutdown the sugar flow manually.) 

Tank 3

The raw sugar in the tank 4 is the flavor. There is an inlet pipe which is used to fill up the tank after being

processed from another department as well as an automated valve to open and close the cycle when

the controller demands. The orange is mixed with some other grinded ingredients or powder to give it

the best flavor. Tank 3 contains an ultrasonic level sensor to detect the level of liquid flavor in the tank,

as well as a flow sensor at the outlet right after the pump valve to ensure of measuring the amount of 

liquid flavor requested by the mixer. When the mixer requests for a certain amount of liquid being

released from the tank 3, it sends a signal to the main controller which on its (in) turn sends a request to

the tank 3 controller to open the valve. When the liquid passes through the outlet, a flow sensor

measures the amount being released from the tank and after, the liquid gets pressured by a pump valve.

An automatic centrifuge instrument is placed after the pump valve to ensure that the orange flavor is

de-oiled or filtered before it reaches the mixer. (this tank to like tank 1 and 2 is also fitted with a manual

valve at its exit as a precaution in case of a system failure or signal failures, it can be used to avoid over

flow) 

Tank 4

Tank 4 is actually the main operating tank in the system as the 3 tanks containing raw materials depend

upon it. It actually possesses 3 flow sensors at each inlet as well as 3 valves. Tank 4 can only contain

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from 500 to 800 kg therefore, a weight sensor is placed underneath the tank in order to prevent an

overweight during the blending of the product. A sleeve jacket is also attached around the tank to keep

it heated as hot liquids from both water and flavor get blended inside. The Tank 4 operates directly with

the main controller as it is placed beside it. In order to get the mixer filled with the raw materials and

get started with the process, the operation does not go simultaneously but sequentially whereby the

water is the first raw material being poured in the tank then followed the sugar and at last the flavor. In

the first sequence, the mixer requests for the water sending signal via a sensor signal transduction to

the main controller which signals to the tank 1 controller to release the water. Once it passes through

the heater, there is a flow sensor to measure the exact amount needed to be poured in the tank. Once it

measures the required amount, it automatically closes the inlet valve, it (then) now requests the tank 2

which follows the procedure explained above then tank 3. Once all the products are poured in the tank,

tank 4 then begins its blending.

Tank 5

Tank 5 is actually the storage tank. It actually(delete acctually) has a level sensor on top and an

automatic inlet valve. When the mixer is done blending the product after a period of time, it sends a

signal to the main controller which on its turn requests the tank 5 controller to open the inlet valve. The

blended product exits the mixer which with help of the pump actually pumps the product in the tank 5.

A level sensor makes sure that the storage level does not exceed the limit or space allotted in the tank 5.

When the product reaches its limit, the sensor signals the tank 5 controller to stop the inlet valve.

DEBUG CHECK (

The plant is actually equipped with a program in case of failure or malfunction mechanism. Therefore, as

stated that the mixer is the main tank requesting for amounts of raw material to be poured in, it actually

has a sensor sensitivity equipped with two signals green and red light. The sensitivity sensor actually

detects if the amount of raw material passing through the flow sensor is accurate or not. If the water or

any tanks has indeed sent an amount below the required ones, the sensitivity sensor signals the main

controller of an error which on its turn displays an alert red light on the controller tank. The sensor

sensitivity is placed right after the flow sensor. Also, taking into account of the time response, it actually

signals an error after a second.

If the flow sensor located on tank 4 calculates the amount being accurate, it sends the signal to

the main controller to turn the light green and proceed with the second process. A stop button is

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actually in the main controller just in case the whole operation has to be shut down in order to trace

where the error might be.

Sensors

Level sensor (ultrasonic): Level sensors detect the level of substances that flow,

including liquids, slurries, granular materials, and powders 

Flow sensor (): Is a device for sensing the rate of fluid flow. 

Sensor signal transduction

Temperature (

Instruments

Pump: