Ps-1 Project Final

8/11/2019 Ps-1 Project Final

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PS-1 PROJECT


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INTRODUCTION


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CENTURY RAYON

Century Rayon is a division of Century textiles

and Ltd which is a constituent of the

prestigious B.K. Birla Group of Industries.

Century Rayon is one of the largest producersof rayon filament yarn in Asia.

The company also produces various

chemicals, namely CS2, H2SO4, Cl2and HCl,which are used both in house (for yarn

production) and the excess is sold to external

customers.


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The Century Rayon division at Shahad has five

major manufacturing plants:-

Rayon Plant

Tyre Cord and CSY Plant

Caustic Plant(Century Chemicals)

Boiler House

Auxiliary Plant(CS2, acid, water and effluent

treatment)


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CENTRAL INSTRUMENTATION

DEPARTMENT


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Functions of the Central

Instrumentation DepartmentTo provide:

Instruments for measuring and monitoringprocess parameters.

Suitable data recording system for processanalysis.

Predictive and preventive measures forplanning and maintenance.

Calibration of instruments as per norms(ISOand non ISO)

Continuous improvement in plants and projectinstallations.


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Measurement of physical parameters like

pressure, temperature, conductivity, etc. are

required to be made precisely and accurately for

many process industries and controlapplications. INSTRUMENTATION is the

science of measurement and control of these

process variables.


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CENTRALINSTRUMENTATION DEPARTMENT

RayonInstrumentati

onDepartment

Tyre CordInstrumentation Department

Auxiliary PlantInstrumentation Department

Boiler andPower House

Instrumentation Department

ChemicalPlant

Instrumentation

Department

CalibrationShop


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STUDY OF FIELD

INSTRUMENTS IN CENTURY

RAYON


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TRANSDUCERS ANDSENSORS


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TRANSDUCERS AND

SENSORS

Devices which convert one form of energy to

another are called TRANSDUCERS.

Some of the transducers employed in modern

measurement techniques are load cells,

Resistance Temperature Detectors,

thermocouples, pressure transmitters etc.


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TRANSDUCERS AND

SENSORS

A SENSOR is a device that measures a physical

quantity and converts it into a signal which can be

read by an observer or by an instrument.

A mercury-in-glass thermometer converts themeasured temperature into an expansion and

contraction of a liquid which can be read on a

calibrated glass tube.

A thermocouple converts temperature to an outputvoltage which can be read by a voltmeter. For

accuracy most sensors are calibrated against

known standards.


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TWO WIRE TRANSMITTERSTHREE WIRE TRANSMITTERS

FOUR WIRE TRANSMITTERS

TYPES OF TRANSMITTERS


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TWO WIRE TRANSMITTERS

Eg: Pressure and Level transmiiters


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THREE WIRE

TRANSMITTERS

Eg: Resistance Temperature

Detectors


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FOUR WIRE TRANSMITTERS

Eg: Flowmeters


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RESISTANCE TEMPERATURE

DETECTOR

THERMOCOUPLE

TEMPERATUREINSTRUMENTS


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RESISTANCE TEMPERATURE

DETECTOR

Resistance temperature detectors (RTDs), are

sensors used to measure temperature by

correlating the resistance of the RTD element

with temperature. The RTD element is made from a pure

material, typically platinum, nickel or copper

wrapped around a ceramic or glass core.

The material has a known change in

resistance as the temperature changes and it

is this known change that is used to determine

temperature.


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Theadvantagesof platinum resistancethermometers include:

High accuracy

Low drift Wide operating range

Suitability for precision applications.

RTD used in industrial applications are used till660C.

Pt 100 and Pt1000 are some of the types ofRTDs used.


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RTD in the Calibration Shop


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THERMOCOUPLE

Imparting heat to the junction of two dissimilar

metals causes a small continuous emf to be

generated. One of the simplest of all temperature

sensors, the thermocouple, depends upon theprinciple known as Seebeck Effect.

By holding temperatures constant at all junctions

except one within a given circuit, we can measure

temperature as a function of the hot junctiontemperature with respect to the cold junction

temperature.


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When readout device is employed, it converts the emf

produced by the temperature difference between hot

and cold junctions to record or otherwise display the

temperature of the hot junction. The types of

Thermocouples are:


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Thermocouples are used in the Boiler House

at Century Rayon to monitor the temperature

of the various sections of the boiler.


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PRESSURE GAUGES

PRESSURE TRANSMITTERS

PRESSURE SWITCHES

DIFFERENTIAL PRESSURE

TRANSMITTERS

PRESSURE MEASURINGINSTRUMENTS


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PRESSURE GAUGES

Bou rdon tub e pressure gauge

When the pressure is applied through the pressure connection, due to

difference in inner and outer radii of Bourdon tube, the tube (which is

filled with oil) tends to straighten and expands upwards. The resulting

tip motion is non-linear which is converted to a linear rotational pointer

response by means by means of a gear sector and pinion movement.


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Pressure Gauges are used in several places in the Rayon and Tyre

Cord and CSY plants VRR department where line pressure is to be

measured and monitored.


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Pressure Gauges are generally of 3 types:

Standalone Pressure Gauge

Oil filled diaphragm Pressure Gauge

Contact Pressure Gauge


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PRESSURE TRANSMITTERS

A pressure transmitter measures pressure and

generates an electric signal as a function of

the pressure imposed.

The pressure sensing elements in electronic

pressure transmitters are modified to the

extent that the force or motion generated bythe process pressure is converted into dc mA

output signals.


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Compared to a pressure gauge a pressuretransmitter:

1. is more accurate

2. has a digital display of the data.3. higher price as compared to pressure gauges.

There are several types of strain/pressuretransmitter depending upon the principle or effect

used to detect various pressures such asdifferential, absolute and gauge pressures.

For the purpose of calibration a HARTcommunicator is used.


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DIFFERENTIAL PRESSURE

TRANSMITTERS

To measure pressure or pressure difference

across two points.

Capacitive type DPT

Differential pressure sensors are used tomeasure many properties, such as pressure

drops across oil filters or air filters, fluid levels

(by comparing the pressure above and belowthe liquid) or flow rates (by measuring the

change in pressure across a restriction).


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PRESSURE SWITCHES

Pressure switches are used to energize and

de-energize electrical circuits as a function of

the relationship between the process pressure

and the pre-determined set points. The relay circuit cuts off and the alarm rings

when the pressure falls out of this range.

They may be used to detect absolute, gaugeand differential pressure.


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TURBINE FLOWMETER

ORIFICE PLATE FLOWMETER

ROTAMETER

ELECTROMAGNETIC FLOWMETER

FLOW MEASURINGINSTRUMENTS


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FLOWMETER

Flow measurement is the quantification of

bulk fluid movement.

Flow can be measured in a variety of ways.

Flow measurement methods rely on forcesproduced by the flowing stream as it overcomes

a known constriction, to indirectly calculate flow.

By measuring the velocity of fluid over a knownarea.


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TURBINE FLOWMETER

Translates the mechanical action of the turbine

rotating in the liquid flow around an axis into a

user-readable rate of flow.


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In the Tyre Cord VRR, there are orifice type flowmeters. The

orifice plate causes a difference in pressure on either side.This differential pressure input goes to the differentialpressure transmitter (DPT). Output of the DPT is a mA signalwhich is then indicated through in m3/hour through a process(flow) indicator.


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Used to measure flow of fluid in vertically placed pipelines in the auxiliary plant.

ELECTROMAGNETIC


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ELECTROMAGNETIC

FLOWMETER

Use Faradays Law of Induction

The fluid itself must have some minimum

conductivity

The instantaneous voltage generated at theelectrodes represents the average fluid

velocity of the flow profile at the plane of the

electrodes at a given instant.


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E=BDV/C

Eis the voltage induced

in conductorproportional tovolumetric flow rate.

Bis the magnetic field

Vis the average

velocity of fluidconductor

Dis the inner diameterof flowmeter

C is the flow coefficient


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Fig: Electromagnetic flowmeter used in the Tyre Cord

VRR to measure the flow of Dope added


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VORTEX FLOWMETER


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pH MEASURING INSTRUMENTS

ELECTRODELESS CONDUCTIVITY

METER

ANALYTICALINSTRUMENTS

pH MEASURING


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pH MEASURING

INSTRUMENTS

pH measurement is based on the use of a pHsensitive electrode (usually glass), a referenceelectrode, and a temperature element to provide atemperature signal to the pH analyser.

pH electrode develops a potential proportional tothe pH of the solution. The reference electrode isdesigned to maintain a constant potential at anygiven temperature.

Most pH sensors produce a 0mV signal at 7 ph. Itis called isopotential point and slope (sensitivity)of -59.16mV/pH at 25 C.


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A Lab pH meter


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CONDUCTIVITY METER

There are two types of Conductivity Meters:- Resistive

- Electrodeless

The electrodeless conductivity system measuresthe resistance of a closed loop of solution.

The cell consists of two toroidal windings on anon-conducting pipe, or metallic non-conductinglined pipe.

One winding is connected to a transmitter whichprovides stable, audio frequency excitationvoltage.

The second winding is connected to a receiverwhich measures its output voltage.


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LEVEL TRANSMITTERS

The level measuring instrument employedthroughout Century Rayon are of varioustypes:

-

Ultrasonic- Differential Pressure (used in the pressurized

tanks)

- Direct Pressure (used in the open tanks)

- Diaphragm The measurement in pressure is converted to

level once the area of column and density ofmaterial are specified.


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Level Transmitter in Rayon VRR


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CONTROL VALVES

-Regulating Valves

-ON/OFF Valves

VALVES


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CONTROL VALVES

These are used to control the opening of thecontrol valves to the desired level and also toregulate the flow.

The level in the tank is measured using a level

transmitter which sends an electrical signal to thecontroller, which in turn generates 4-20 mA outputsignal. This goes as input to the I to P converterand the output is of pneumatic type which goes to

the control valve. In the I to P converter there isan inlet air stream which is regulated such that ithas a pressure corresponding to the signalreceived.


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Control Valve Set-up in the Rayon VRR room

These valves are installed in the supply lines to the

receiving tanks for the purpose of holding constant

pressure and to prevent overflow.


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ON/OFF VALVES

They have two states- ON/OFF. They are notused to regulate the amount of flow.

The Inlet and Outlet valves of the Receiving

Tanks in the Rayon VRR room are On/Offvalves.

Limit Switches are used to indicate the state ofthe valves.

Colour Code used: GreenON i.e. The valve is open.

RedOFF i.e. The valve is closed.


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Red showing that the valve is closed or OFF


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PROCESS INDICATOR/CONTROLLER

PROGRAMMABLE LOGIC

CONTROLLER

PROCESS CONTROLLINGDEVICES


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PROCESS INDICATOR PANEL IN TYRE

CORD VRR

PROGRAMMABLE LOGIC


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PROGRAMMABLE LOGIC

CONTROLLER

Programmable logic controllers(PLCs) are

members of the computing family capable of

storing instructions to control functions such as

sequencing, timing and counting, which controla machine or a process.

They are devices that are capable of being

programmed to perform a controlling function.


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PLCs measure input signals coming from a

machine and through the internal program

provide output or control back to the machine.

Ladder logic is the programming language

used to represent electrical sequences of

operation.


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PLC panel in the Rayon plant VRR receiving tanks


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STUDY OF PROGRAMMABLELOGIC CONTROLLER SYSTEM

IN RAYON VRR RECEIVINGTANKS SECTION

S C ?


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WHAT IS A PLC ?

They are members of the

computing family capable

of storing instructions to

control functions such as

sequencing, timing and

counting, which control a

machine or a process.


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PLCs measure input signals coming from a

machine and through the internal program

provide output or control back to the machine.

Ladder logic is the programming language

PLCs are soft wired.

BEFORE PLCs: MANUAL


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BEFORE PLCs: MANUAL

OPERATION

Before the advent of relays and PLCs thecontrol operations in industries were carriedout manually.

There is scope of errors due to humaninefficiency.

DISADVANTAGES:

Large work force required

Precise control and timing difficult due tohuman errors

Someone had to be present at the site at allthe times.

BEFORE PLC RELAYS


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BEFORE PLCs: RELAYS

A Relay has an electromagnetic coil and three ports: Common

(COM), normally Open (NO) and Normally Closed (NC).

When the coil is energized, the NO gets connected to COM

and NC gets disconnected i.e NC becomes NO and NO

becomes NC. This provides a conducting path for electricity to

the motor (or any other equipment) and it starts running.


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DISADVANTAGES: Involve a vast amount of interconnection.

High costs due to extensive wiring.

To minimize this cost the relay and logic blocks had tobe kept together.

Control panels were huge and required a lot of space.

Detection of errors in system was difficult due toextensive wiring

For replacement of relays machine had to stopped and

production as well. Hold-up time was indefinite, usuallyvery long.

A control panel was used only for one particular process,and wasnt easy to adapt to the requirements of a newsystem.

ADVANTAGES OF THE PLC


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ADVANTAGES OF THE PLC

SYSTEM

Flexibility in control based on programming andexecuting logic instructions.

Number of wires needed for connections is reduced

by approximately 80%.

Diagnostic functions of a PLC controller allow for

fast and easy error detection.

Change in operating sequence or application of a

PLC controller to a different operating process caneasily be accomplished by replacing a program

through console or using PC software (not requiring

changes in wiring, unless addition of some input or

output device is required).


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BASIC COMPONENTS OF PLC


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BASIC COMPONENTS OF PLC

SYSTEM

Rack Assembly Power Supply

Central Processing Unit

Input/Output System

- Digital Input- Digital Output

- Analog Input

- Analog Output

Memory

Programming Languages

PLC Bl k Di


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PLC Block Diagram

LADDER LOGIC


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LADDER LOGIC

Rule-based language A rung in the ladder represents a rule. When

implemented in a programmable logic controller, therules are typically executed sequentially by software,

in a continuous loop. -- ( ) -- a regular coil, energized whenever the rung is

closed.

-- (\) -- a not coil, energized whenever the rung is

open. -- [ ] -- a regular contact, closed whenever its

corresponding coil or an input which controls it isenergized.

-- [\] -- a not contact, open whenever itscorres ondin coil or an in ut which controls it is


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The picture above has a single circuit or rung of ladder.

If input1 is ON (or true)power (logic) completes the circuit

from the left rail to the right railand Output 1 turns ON (ortrue).

If Input 1 is OFF (or false)then the circuit is not completed

and logic does not flow to the right - and Output 1 is OFF.


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COMPANY

AllenBradly

Siemens

ModiconABB

Mitsubishi

CLASSIFICATION OF PLC


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CLASSIFICATION OF PLCs

I/OCOUNT

Small(


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RECEIVING TANK SECTION OF


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RAYON VRR

Viscose is stored in the 7 receiving tanks afterthe first stage of filtration for a specific period

of time to facilitate ripening.

ABB make PLC system used to automate theprocess.

2 sequences:

Filling sequence Emptying sequence

CURRENT SET POINTS OF THE


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TANKS

LEVEL VOLUME

LOW LOW 0.1 m3

LOW 1 m3

HIGH 11 m3

HIGH HIGH 14 m3

Alarm rings when the volume of viscose reaches low/ high.

The output pump trips when the volume of viscose reaches low low

and the input pump trips when the volume reaches high high.

Bypass Situation: When a tank has to be repaired, it is given priority 0

and the air supply is closed so that the inlet and outlet valves are never

open.

PLC CONTROL PANEL


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PLC CONTROL PANEL

CPU AND I/O MODULE


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CPU AND I/O MODULE

RELAYS


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RELAYS

POWER SUPPLY AND FUSE


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TV

POWER SUPPLY FUSE TV

MINIATURE CIRCUIT


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BREAKER

I/O TERMINAL BOARDS


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I/O TERMINAL BOARDS

HUMAN MACHINE


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INTERFACE

The PLC panel communicates with the HumanMachine Interface (HMI).


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The opening and closing of the inlet/outletvalves of individual tanks can also be

regulated manually.


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HMI also has an option to show the history ofthe past alarms which may help in future

analysis.


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Tank level set points which are fixed for all theseven tanks.


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HMI also has an option to show the status ofthe inlet and outlet pumps.


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Priority sequence of the tanks.

LOGIC SEQUENCE OF VRR


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RECEIVING TANKS

The example of the filling sequence is asfollows:Tank 1, tank2, tank3, tank4, tank5, tan6,

tank7, tank1The change over from tank1to tank2 should take place when the high setpoint of the level is reached.

The sequence should be the inlet valve oftank 2 should get opened. When the openconfirm of that inlet valve is received, and thenthe inlet valve of tank 1 should get closed.


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The example of emptying sequence is asfollows:Tank2, tank3, tank 4, tank5, tank6, tank7,

tank1, and tank2..The change over fromtank2 to tank 3 should be when the low setpoint of the level is reached.

The sequence should be the outlet valve oftank 3 should get open. When the openconfirm of that outlet valve is received thenthe outlet valve of tank 2 should get closed.

RECEIVING TANK AUTO CHANGEOVER


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SYSTEM

Tank I/L valve OPEN

Tank I/L valve CLOSE

Tank O/L valve OPEN

Tank O/L valve CLOSE

GCF Feed Pumps trip

PD Pumps trip

There are colour codes to represent the statusof valves and pumps.

PLC FROM MANUAL TO AUTO


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MODE

Example, if tank 2 is selected in beginning thefilling sequence will be 2, 3, 4, 5, 6, 7, 1 and

emptying out sequence will be 3, 4, 5, 6, 7, 2,

1. If we do not want to empty out the tank which

is next to the tank under filling then the tank or

tanks can be bypassed by giving a value 0 to

the tank or tanks in the tank emptying outsequence. This can be done from tank filling

empty sequence window on PLC panel.


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CONDITIONS FOR OPENING I/L VALVEOF TANK IN THE BEGINNING

Priority number 1 should be given

Tank level should be LOW.(Red strip indicatesLOW level of tank)

Tank O/L valve should be CLOSE.

Tank should not be bypassed.


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CONDITIONS FOR OPENING O/L VALVE OFTANK IN THE BEGINNING

Tank should not be bypassed

Tank level should be HIGH.( Red stripindicates high level of tank)

Tank I/L valve should be CLOSE.

PLC FROM AUTO TO MANUAL


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MODE

Stop GCF pumps 5A/5B and PD pump1/ pump2.

Take the system on MANUAL from the knob

provided on the panel. Open I/L and O/L valves of the tanks which

were on line from the knobs on PLC panel.

Start GCF pumps 5A/5B and PD pumps

1/pump 2.


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THANK YOU!!-BHAVYA VAID

-NIKITA TANWANI

-SHALINI MITRA-SHRESHTHA MITRA

-SHRUTI KUMAR

Ps-1 Project Final

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