PS-1 PROJECT

INTRODUCTION
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 producers
of rayon filament yarn in Asia.
The company also produces various
chemicals, namely CS
2
, H
2
SO
4
, Cl
2
and HCl,
which are used both in house (for yarn
production) and the excess is sold to external
customers.
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(CS
2
, acid, water and effluent
treatment)


CENTRAL INSTRUMENTATION
DEPARTMENT
Functions of the Central
Instrumentation Department
To provide:
Instruments for measuring and monitoring
process parameters.
Suitable data recording system for process
analysis.
Predictive and preventive measures for
planning and maintenance.
Calibration of instruments as per norms(ISO
and non ISO)
Continuous improvement in plants and project
installations.
Measurement of physical parameters like
pressure, temperature, conductivity, etc. are
required to be made precisely and accurately for
many process industries and control
applications. INSTRUMENTATION is the
science of measurement and control of these
process variables.
CENTRAL
INSTRUMENTATIO
N DEPARTMENT
Rayon
Instrumentati
on
Department
Tyre Cord
Instrumentatio
n Department
Auxiliary Plant
Instrumentatio
n Department
Boiler and
Power House
Instrumentatio
n Department
Chemical
Plant
Instrumentati
on
Department
Calibration
Shop
STUDY OF FIELD
INSTRUMENTS IN CENTURY
RAYON
TRANSDUCERS AND
SENSORS
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.
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 the
measured temperature into an expansion and
contraction of a liquid which can be read on a
calibrated glass tube.
A thermocouple converts temperature to an output
voltage which can be read by a voltmeter. For
accuracy most sensors are calibrated against
known standards.


TWO WIRE TRANSMITTERS
THREE WIRE TRANSMITTERS
FOUR WIRE TRANSMITTERS
TYPES OF TRANSMITTERS
TWO WIRE TRANSMITTERS
Eg: Pressure and Level transmiiters
THREE WIRE
TRANSMITTERS
Eg: Resistance Temperature
Detectors
FOUR WIRE TRANSMITTERS
Eg: Flowmeters
RESISTANCE TEMPERATURE
DETECTOR
THERMOCOUPLE
TEMPERATURE
INSTRUMENTS
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.

The advantages of platinum resistance
thermometers include:
High accuracy
Low drift
Wide operating range
Suitability for precision applications.
RTD used in industrial applications are used till
660C.
Pt 100 and Pt1000 are some of the types of
RTDs used.

RTD in the Calibration Shop
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 the
principle 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 junction
temperature with respect to the cold junction
temperature.

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:

Thermocouples are used in the Boiler House
at Century Rayon to monitor the temperature
of the various sections of the boiler.

PRESSURE GAUGES
PRESSURE TRANSMITTERS
PRESSURE SWITCHES
DIFFERENTIAL PRESSURE
TRANSMITTERS
PRESSURE MEASURING
INSTRUMENTS
PRESSURE GAUGES
Bourdon tube 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.


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.

Pressure Gauges are generally of 3 types:

Standalone Pressure Gauge

Oil filled diaphragm Pressure Gauge

Contact Pressure Gauge


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 by
the process pressure is converted into dc mA
output signals.
Compared to a pressure gauge a pressure
transmitter:
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/pressure
transmitter depending upon the principle or effect
used to detect various pressures such as
differential, absolute and gauge pressures.
For the purpose of calibration a HART
communicator is used.

DIFFERENTIAL PRESSURE
TRANSMITTERS
To measure pressure or pressure difference
across two points.
Capacitive type DPT
Differential pressure sensors are used to
measure many properties, such as pressure
drops across oil filters or air filters, fluid levels
(by comparing the pressure above and below
the liquid) or flow rates (by measuring the
change in pressure across a restriction).

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, gauge
and differential pressure.

TURBINE FLOWMETER
ORIFICE PLATE FLOWMETER
ROTAMETER
ELECTROMAGNETIC FLOWMETER
FLOW MEASURING
INSTRUMENTS
FLOWMETER
Flow measurement is the quantification of
bulk fluid movement.
Flow can be measured in a variety of ways.
Flow measurement methods rely on forces
produced by the flowing stream as it overcomes
a known constriction, to indirectly calculate flow.
By measuring the velocity of fluid over a known
area.

TURBINE FLOWMETER
Translates the mechanical action of the turbine
rotating in the liquid flow around an axis into a
user-readable rate of flow.

ORIFICE PLATE FLOWMETER
An orifice plate is a plate with a hole through it;
placed in the flow, it constricts the flow, and by
measuring the pressure differential across the
constriction gives the flow rate.







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 differential
pressure transmitter (DPT). Output of the DPT is a mA signal
which is then indicated through in m
3
/hour through a process
(flow) indicator.


ROTAMETER (Variable Area
Flowmeter)
The working principle is the Bernoullis
Principle
When fluid or gas flows through a taper tube
containing a float, a pressure difference of P
and P is created between upper and lower
side of the float. The float moves upwards by a
force obtained by multiplying the pressure
differential by the maximum cross sectional
area of the float.



Used to measure flow of fluid in vertically placed pipelines in the auxiliary plant.
ELECTROMAGNETIC
FLOWMETER
Use Faradays Law of Induction
The fluid itself must have some minimum
conductivity
The instantaneous voltage generated at the
electrodes represents the average fluid
velocity of the flow profile at the plane of the
electrodes at a given instant.

E=BDV/C

E is the voltage induced
in conductor
proportional to
volumetric flow rate.
B is the magnetic field
V is the average
velocity of fluid
conductor
D is the inner diameter
of flowmeter
C is the flow coefficient


Fig: Electromagnetic flowmeter used in the Tyre Cord
VRR to measure the flow of Dope added

VORTEX FLOWMETER
pH MEASURING INSTRUMENTS
ELECTRODELESS CONDUCTIVITY
METER

ANALYTICAL
INSTRUMENTS
pH MEASURING
INSTRUMENTS
pH measurement is based on the use of a pH
sensitive electrode (usually glass), a reference
electrode, and a temperature element to provide a
temperature signal to the pH analyser.
pH electrode develops a potential proportional to
the pH of the solution. The reference electrode is
designed to maintain a constant potential at any
given temperature.
Most pH sensors produce a 0mV signal at 7 ph. It
is called isopotential point and slope (sensitivity)
of -59.16mV/pH at 25 C.

A Lab pH meter
CONDUCTIVITY METER
There are two types of Conductivity Meters:
- Resistive
- Electrodeless
The electrodeless conductivity system measures
the resistance of a closed loop of solution.
The cell consists of two toroidal windings on a
non-conducting pipe, or metallic non-conducting
lined pipe.
One winding is connected to a transmitter which
provides stable, audio frequency excitation
voltage.
The second winding is connected to a receiver
which measures its output voltage.


LEVEL TRANSMITTERS
LEVEL MEASURING
INSTRUMENTS
LEVEL TRANSMITTERS
The level measuring instrument employed
throughout Century Rayon are of various
types:
- 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 of
material are specified.

Level Transmitter in Rayon VRR
CONTROL VALVES
- Regulating Valves
- ON/OFF Valves
VALVES
CONTROL VALVES
These are used to control the opening of the
control valves to the desired level and also to
regulate the flow.
The level in the tank is measured using a level
transmitter which sends an electrical signal to the
controller, which in turn generates 4-20 mA output
signal. This goes as input to the I to P converter
and the output is of pneumatic type which goes to
the control valve. In the I to P converter there is
an inlet air stream which is regulated such that it
has a pressure corresponding to the signal
received.


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.

ON/OFF VALVES
They have two states- ON/OFF. They are not
used to regulate the amount of flow.
The Inlet and Outlet valves of the Receiving
Tanks in the Rayon VRR room are On/Off
valves.
Limit Switches are used to indicate the state of
the valves.
Colour Code used:
Green ON i.e. The valve is open.
Red OFF i.e. The valve is closed.

Red showing that the valve is closed or OFF
PROCESS INDICATOR/CONTROLLER
PROGRAMMABLE LOGIC
CONTROLLER

PROCESS CONTROLLING
DEVICES
PROCESS
INDICATOR/CONTROLLER
It is an instrument for providing indication as
well as controlling set points to various
processes.
It is designed to accept various process inputs
(Current, Voltage, RTD, Thermocouples,
Resistances) simultaneously i.e. in
UNIVERSAL manner or any one of these in
PREDEFINED manner.

PROCESS INDICATOR PANEL IN TYRE
CORD VRR
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 control
a machine or a process.
They are devices that are capable of being
programmed to perform a controlling function.
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.


PLC panel in the Rayon plant VRR receiving tanks
STUDY OF PROGRAMMABLE
LOGIC CONTROLLER SYSTEM
IN RAYON VRR RECEIVING
TANKS SECTION
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.
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
OPERATION
Before the advent of relays and PLCs the
control operations in industries were carried
out manually.
There is scope of errors due to human
inefficiency.
DISADVANTAGES:
Large work force required
Precise control and timing difficult due to
human errors
Someone had to be present at the site at all
the times.

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.

DISADVANTAGES:
Involve a vast amount of interconnection.
High costs due to extensive wiring.
To minimize this cost the relay and logic blocks had to
be kept together.
Control panels were huge and required a lot of space.
Detection of errors in system was difficult due to
extensive wiring
For replacement of relays machine had to stopped and
production as well. Hold-up time was indefinite, usually
very long.
A control panel was used only for one particular process,
and wasnt easy to adapt to the requirements of a new
system.

ADVANTAGES OF THE PLC
SYSTEM
Flexibility in control based on programming and
executing 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 can
easily 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).
Needs fewer spare parts

Cheaper compared to conventional system
especially in cases where a large number of I/O
instruments are needed and where operational
functions are complex.
Greater reliability than that of an electro-
mechanical relay of a timer, because of less
moving parts.
Compact and occupy less space
Savings in Hardware and winding costs.
Less manual involvement is required.
Control panels can be operated for a distant
control room through HMI; making control and
operation easier.

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 Block Diagram
LADDER LOGIC
Rule-based language
A rung in the ladder represents a rule. When
implemented in a programmable logic controller, the
rules 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 is
energized.
-- [\] -- a not contact, open whenever its
corresponding coil or an input which controls it is
energized.


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 rail and Output 1 turns ON (or
true).
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.

COMPANY
Allen
Bradly
Siemens
Modicon ABB
Mitsubishi
CLASSIFICATION OF PLCs
I/O
COUNT
Small
(<256)
Medium
(<1024)
Large
(>1024)
Micro
(<32)
HOUSING OF
COMPONENTS
MODULAR
NON-
MODULAR
RECEIVING TANK SECTION OF
RAYON VRR
Viscose is stored in the 7 receiving tanks after
the first stage of filtration for a specific period
of time to facilitate ripening.
ABB make PLC system used to automate the
process.
2 sequences:
Filling sequence
Emptying sequence

CURRENT SET POINTS OF THE
TANKS
LEVEL VOLUME
LOW LOW 0.1 m
3

LOW 1 m
3

HIGH 11 m
3

HIGH HIGH 14 m
3

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
CPU AND I/O MODULE
RELAYS
POWER SUPPLY AND FUSE
TV
POWER SUPPLY
FUSE TV
MINIATURE CIRCUIT
BREAKER
I/O TERMINAL BOARDS
HUMAN MACHINE
INTERFACE
The PLC panel communicates with the Human
Machine Interface (HMI).

The opening and closing of the inlet/outlet
valves of individual tanks can also be
regulated manually.

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

Tank level set points which are fixed for all the
seven tanks.

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

Volume of viscose in each tank.


Priority sequence of the tanks.

LOGIC SEQUENCE OF VRR
RECEIVING TANKS
The example of the filling sequence is as
follows:
Tank 1, tank2, tank3, tank4, tank5, tan6,
tank7, tank1The change over from tank1
to tank2 should take place when the high set
point of the level is reached.
The sequence should be the inlet valve of
tank 2 should get opened. When the open
confirm of that inlet valve is received, and then
the inlet valve of tank 1 should get closed.

The example of emptying sequence is as
follows:
Tank2, tank3, tank 4, tank5, tank6, tank7,
tank1, and tank2..The change over from
tank2 to tank 3 should be when the low set
point of the level is reached.
The sequence should be the outlet valve of
tank 3 should get open. When the open
confirm of that outlet valve is received then
the outlet valve of tank 2 should get closed.

LIST OF INTERLOCKS FOR S/VRR
RECEIVING TANK AUTO CHANGEOVER
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 status
of valves and pumps.

PROCEDURE FOR STARTING THE
PLC FROM MANUAL TO AUTO
MODE

Example, if tank 2 is selected in beginning the
filling 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 out
sequence. This can be done from tank filling
empty sequence window on PLC panel.
CONDITIONS FOR OPENING I/L VALVE
OF TANK IN THE BEGINNING
Priority number 1 should be given
Tank level should be LOW.(Red strip indicates
LOW level of tank)
Tank O/L valve should be CLOSE.
Tank should not be bypassed.

CONDITIONS FOR OPENING O/L VALVE OF
TANK IN THE BEGINNING
Tank should not be bypassed
Tank level should be HIGH.( Red strip
indicates high level of tank)
Tank I/L valve should be CLOSE.

PROCEDURE FOR STARTING THE
PLC FROM AUTO TO MANUAL
MODE

Stop GCF pumps 5A/5B and PD pump1/ pump
2.
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.

THANK YOU!!
-BHAVYA VAID
-NIKITA TANWANI
-SHALINI MITRA
-SHRESHTHA MITRA
-SHRUTI KUMAR