Loop Diagram (LD) As engineers are looking at process flow diagram the technician look at loop diagram . In the loop diagram, you can find interconnection of individual instruments, wire number, terminal number, calibration range etc. It shows a complete loop of an individual instrument with all above mentioned datails.

Piping and Instrumentation Diagram (P&ID) Piping and instrumentation diagrams (P&IDs) lie somewhere in the middle between process flow diagram and loop diagrams. Piping and instrumentation shows the layout of all relevent process vessels, pipes, and machinery, but with instruments superimposed on the diagram showing what gets measured and what gets controlled. Here, one can view the flow of the process as well as the information between instruments measuring and controlling the process.

process variables, classify input and output variables, determine control objectives and appropriate manipulated variables for Evaporators Process Variables Level of Solution, Temperature of Solution, Concentration Density. Input Variables Dilute feed Solution, Steam Flow. Output Variables Vapor, Steam, Product. Control Objectives The main objective of evaporators is to get a concentrated product by vaporizing volatile liquid, Out evaporation process, Evaporation is conducted by non volatile solids and volatile solvent to produce this liquid. Manipulated Variables Flow Rate of the feed solution, Discrete signal of the outlet value control.

process variables, classify input and output variables, determine control objectives and appropriate manipulated variables for Evaporators Process Variables Level of Solution, Temperature of Solution, Concentration Density. Input Variables Dilute feed Solution, Steam Flow. Output Variables Vapor, Steam, Product. Control Objectives The main objective of evaporators is to get a concentrated product by vaporizing volatile liquid, Out evaporation process, Evaporation is conducted by non volatile solids and volatile solvent to produce this liquid. Manipulated Variables Flow Rate of the feed solution, Discrete signal of the outlet value control.

process variables, classify input and output variables, determine control objectives and appropriate manipulated variables for Dryers Process Variables  Temperature, Drying Period, Surrounding Temperature. Input Variables  Feed Flow, Input Temperature of Dry Air, Input Moisture of Solid and Feed Flow . Output Variables  Dred Product Moisture Content, Exhoust Air Temperature, The Temperature of Air Product  mixture (for spray dryers), Exhaust air Humidity, Product Quality (S, flavour, textures, activity, etc.); these properties are generally difficult (or impossible) to measure online and the cost is often too high. Control Objectives maintenance of Dried Product Quality, Maxima of throughout of optimal, Energy efficiency and minimum cost, Stability of process. Manipulated Variables Heating rate (e.g., inlet air or steam temperature), Solids feed rate (e.g., screw conveyor speed, discharge rate), Airflow rate (for direct dryers), Rotational speed (for rotary dryers)

Recipe Management System  A recipe management system is a software application that manages the complex relationships and processes related to a company’s production recipes. They store the recipes, enable recipe modification, generate data required for production records, and even provide the ability to launch tasks and processes. Recipe management systems are most effective when integrated with a manufacturing execution system (MES) or other higher-level control systems. Recipe management can also be a module within an MES. In manufacturing, a recipe is a set of instructions or steps needed to operate a machine, combine ingredients or raw materials in a certain way and in certain ratios, or otherwise process the materials to achieve the desired end product. Common Features of a Recipe Management System Recipe versioning. Recipe archiving. Allocation of equipment. Automation of recipe procedures. Product variant control between similar products. Generation of material flow, execution

Batch Process Management Batch process management involves various activities like process control, unit supervision, process management, production planning and scheduling, production management, management of production information, and recipe management.  A batch management system based on ISA S88 allows the physical model to be created based on the P&I diagrams and a database of all materials. Batch Management System is a separate system at the supervisory level in the control system hierarchy. It uses an open database like SQL Server for storing the materials data and the recipe information. Although the S88 standard was available since 1995, it was not very popular since the Batch Management Systems based on it were far too expensive and its implementation required a lot of customization, which in turn required highly skilled engineers for implementation and support. The automation systems in those days were also not so open and flexible, which made adapting to such Batch Man

Characteristics of Dryer The requirements and characteristics of any industrial dryer control system are 4 Accuracy Stability Speed of response Robustness Accuracy:  The exit product moisture content must be close to the desired value. Stability:  The system must not oscillate; otherwise, large fluctuations in output moisture content would occur. Speed of response:  Any disturbances (e.g., changes in input moisture content) should be quickly offset by the controller in order to provide acceptable upset recovery time and system stability. Robustness:  The control system should be able to operate successfully over a wide range of process conditions.

Objectives of Dryers   The basic objectives of a dryer control system are  Maintenance Maximization Avoidance  Reduction  Suppression  Stable  Optimization Maintenance : Maintenance of desired dried product quality, irrespective of disturbances in the drying operation and variations in feed supply Maximization : Maximization of throughput at optimal energy efficiency and minimum cost. Avoidance : Avoidance of over drying and under drying; under drying may result in spoilage, in the case of grains and foodstuffs, whereas over drying of the product results in increased energy costs and reduced yields as the price of some products is based on a specific moisture content; it may also cause thermal damage to heat-sensitive products  Reduction : Reduction of fire hazard, defective product, and particle emission Suppression : Suppression of the influence of external disturbances Stable : Stable drying process Optimization : Optimization of the performance of the drying process

Questions And Answers On Industrial Internet Of Things 1. ___ is a subset of machine learning that can learn automatically by finding the features of the object on its own. a) Deep learning b) Artificial intelligence c) Human learning d) None of the above Answer: Deep learning 2. SQL stands for_____ a) Structured Query Language b) Semantic Query Language c) Source Query Language d) Safe Query Language Answer: Structured Query Language 3. Which of the following is not a characteristic of Big Data ? a) Velocity b) Veracity c) Vitality d) Value Answer: Vitality 4. HDFS is a file system derived from open-source codes of ____. a) Smart FS b) KFS c) GFS d) None of the above Answer: GFS 5. Which of the following feature(s) is/are essential for cloud-based analytics methods as per NIST? a) Wide network access b) Method grouping c) Fast flexibility d) All of the above Answer: All of the above 6. Which of the following is/are the component(s) of Cyber Security? a) Application security b) Informa

Need of automated industry Automation in the industrial workplace provides the advantages of improving productivity and quality while reducing errors and waste, increasing safety, and adding flexibility to the manufacturing process. Industrial automation yields increased safety, reliability, and profitability. These systems make automation possible for factories and industrial processes, allowing a continuous mass production 24/7. 24 hours a day, seven days a week, which improves productivity and reduces assembly times By means of adaptive control and monitoring in different stages and industrial processes, these systems are useful in eliminating human error and thus improve the quality and homogeneity of the products offered. The performance is not reduced after several hours of continuous work Improved worker safety Automated cells remove workers from dangerous tasks. Your employees will thank you for safeguarding them against the hazards of a factory environment. Increased productio

Industrial Automation Tools Industrial Automation Tools are the technologies that control and manage systems and devices. Moreover, these tools reduce the possibility of human errors, decrease costs, save time, etc.  Different types of automation tools used in industry DCS :  Monitoring networks PLC : Multiple input and output arrangement SCADA : Find new ways to operate faster HMI : Helps to Control industrial automation equipment ANN : Responsible in processing information Robotics DCS DCS stands for Distributed Control System. Distributed Control System is one of the most popular industrial automation tools. It also caters to multiple processes in the manufacturing industry. Moreover, it contains one or more controller components distributed in the system. PLC PLC stands for Programmable Logic Controller. A Programmable Logic Controller or PLC is a robust digital industrial computer control system. It is preprogrammed to execute automatic operations in the manufacturing process.

Basic Control Strategies Used in Industrial Control System How well the process parameters are controlled depends on the control strategy implemented for that process. Basic control strategies used in most of the industries are ON – OFF Control Open-Loop Control Feed- Forward Control Closed-Loop control ON – OFF Control It is also called as two- position control system that has only two states fully on and fully off. It is the oldest type of control strategy that gives simple on- off mechanism for the set limits. When the process variable (PV) or measurement is below the set limit, then the controller is switched ON and the manipulated variable (MV) changes to maximum value. Similarly, if the PV is above the set limit, then the controller gets turned OFF and the MV changes to minimum value. Open-Loop Control In this control structure, control action is not a function of process variable or any load changes. This is also not a self-correcting one. This control scheme independently calcu

Automation pyramid Levels of Automation Pyramid Level 0:   Field Level/Production Process Level 1:  Control Level/Sensing and Manipulation Level 2:  Supervisory Level/Monitoring and supervising Level 3:  Planning Level/Operations Management Level 4:  Enterprise Level(Business Planning and Logistics) Level 5:  Cloud Level 0: Field Level/Production Process This level has devices, actuators, and sensors that are found in the field or on the production floor. The field level is the production floor where physical work and monitoring happens. Electric motors, hydraulic and pneumatic actuators to move  machinery, proximity switches to detect movement of certain materials,  photoelectric switches that detect similar things are some examples at the field  level. Level 1: Control Level/Sensing and Manipulation PLC’s and PID’s operate at this level. At this level, you control and manipulate the devices in the field level that actually do the physical work. Level 2: Supervisory Level/Monitoring a

Cascade control strategy used for control of temperature in an exothermic chemical reactor

Steam Pressure Control in Boiler Steam pressure is the key variable that indicates the state of balance between the supply and demand for steam. If supply exceeds demand, the pressure will rise. Conversely, if demand exceeds supply, the pressure will fall. Plants may experience fluctuations in demand due to batch processes or other process changes. In this case, a steam flow feedforward signal is used with steam pressure control. The term Plant Master is most applicable to the situation in which more than one boiler supplies a common steam header. In this case, there are multiple boiler masters but only one plant master. The plant master generates the master firing rate demand signal that drives the individual boilers in parallel. With multiple boilers, the Plant Master is typically configured with a variable gain, based on the number of boilers in automatic mode. 

Shrink and Swell effect in boiler Shrink  effect  Now as the steam pressure starts increasing steadily the boiler pressure increases and boiling point of water also starts increasing which lead to decrease in bubble formation and level starts dropping and water level seems decreasing. Now automatic water level control valve opens and cool water enters the system and bubbles burst leading to decrease in level of water more. This effect is called shrinkage. Swell effect  Let us suppose discharging of cargo in a tanker is going on. Now due to sudden increase in steam demand due to starting of another copt or due to sudden increase in rpm of copt’s there is a sudden drop in boiler pressure. This sudden drop in pressure leads to vapourization of water as boiling point of water decreases with decrease in pressure. Hence the formation of bubbles inside the boiler makes the level of water looks like increased which in real in not there. This phenomenon is known as swelling which leads to closu

Air and Fuel Ratio Control In Combustion processes, air/fuel ratio is normally expressed on a mass basis. We get maximum useful heat energy if we provide air to the combustion zone at a mass flow rate (e.g. ib/min, kg/hr) that is properly matched to the mass flow rate of fuel to the burner. Air and fuel ratio control Consider this generic equation for fuel combustion chemistry: Fuel + Air =Useful heat + CO2 + H2O + CO + Unburned Fuel + Waste Heat Up the Stack ( CO + Unburned Fuel ) Increases as combustion air Decreases  ( Waste Heat Up the Stack ) Increases as combustion air Increases  Where CO2 = Carbon dioxide  CO = Carbon monoxide  H2O = Water  Air = 21% oxygen (O2) and 79% nitrogen (N2)  Fuel = Hydrocarbon such as natural gas or liquid fuel oil  Normally Air/Fuel ratio control is known as series control This means the change in air flow rate occurs as per ratio set only after the change has occurred in fuel flow rate. But in boilers used in power plants, fuel and air should be cont

Burner Management System  A burner management system(BMS) is a safety solution that manages a combustion system and is responsible for Start-up and main flame detection Control and monitoring  Shutdown sequences  The BMS is considered a safety instrumented system (SIS). In  PLC technology is used, it is often based on 1oo2 (one-out-of-two) or 2oo3d (two-out-of-three diagnostics) logic BMS interlocks must be implemented with dedicated systems. It can be accomplished by hard-wired relay logic, solid-state logic, or PLCs. Burner management systems are engineered to provide igniters (pilot) and main flame detection, as well as control and monitoring of burner start-up and shutdown sequences. This systems can help protect people, combustion process equipment, and surroundings areas in the event of an explosion or hazardous incident. BMS includes alarm management and operator display. These features help simplify unit operation while reducing start-up time. Purpose of BMS To inhibit startup