Ministry of Defence, India
Design, supply, installation & commissioning of PLC & SCADA Based Automatic Temperature Control System for 2 No’s of vessels.
The customer is the pioneer manufacture of quality propellants for different types of ammunitions including 105mm, 120mm, 130mm, 155mm, propellant for naval ammunition and small arms. The factory’s production plant consists of different vessels and the system uses water jackets to regulate temperature by adjusting the water flow through the jackets using manual valves. The manual operating system had many problems like unpredictable temperature variations, accidents, unavailability of past data etc. CONSYST Proposed an Automatic Temperature Control System using PLC, SCADA, Field Sensors, and Automated Field Actuators for two numbers of Vessels at one of the manufacturing facility at the plant. By implementing the new system, the operator can easily start the system by setting the temperature set point from SCADA and clicking the start button. The system will take the temperature feedback from the sensors installed in the field and automatically control the temperature by adjusting the hot and cold water valves using the PID logic written indie the PLC.
Through controlled circulation of hot and cold water, the PID algorithm can maintain the Critical process temperature. To maintain the temperature inside vessels, inlet and outlet provisions are provided to circulate hot and cold water. The temperature of the vessel is measured using a thermocouple and is transmitted to the PLC using a temperature transmitter. The PID output from the controller controls the temperature by pneumatic control valves. Control valves are used to circulate hot and cold water for raising and lowering the temperature inside the vessels. A bypass valve is also provided for emergency requirements. The PLC is integrated with a SCADA system to monitor the entire process on a real time basis in the SCADA screen and historize the data to its Database. The mode of operation for different propellant can be selected from SCADA screen and user can enter the temperature set point through SCADA. The temperatures of both the vessels will be shown on SCADA screen and also shows the direction of the motor inside the vessels, motor power consumption, machine idle time, operator caution alarms, auto mode failure, high-temperature alarm, safety alarm, and safety shutdown alarm, etc.