Control Modules

ControlModule                   Description                                                       Type

101LSH-                 1 High Level Switch For Tank 101                                DI

101LSL-                  1 Low Level Switch For Tank 101                                DI

 201LSH-                 1 High Level Switch For Tank 201                                 DI

201LSL-                 1 Low Level Switch For Tank 201                                 DI

 301LSH-                1 High Level Switch For Tank 301                                  DI

 301LSL-                 1 Low Level Switch For Tank 301                                  DI

   101SOV-                 1Inlet Valve For Tank 101                                            DO

   201SOV-                  1Inlet Valve For Tank 201                                           DO

   301SOV-                 1Inlet Valve For Tank 301                                            DO

   101AV-                 1 Outlet Valve For Tank 101                                           DO

     201AV-                 1 Outlet Valve For Tank 201                                             DO

   301AV-                 1 Outlet Valve For Tank 301                                            DO

   401AV-                   1 Inlet Valve For Tank 401                                            DO

   401SOV-               1Outlet Valve Fine For Tank 401                                      DO

  401AV-                  2 Outlet Valve Coarse For Tank 401                                DO

   401M-                        1 Agitator DOPUMP Pump                                          DO

401LT-                    1 Level Transmitter For Tank 401                                 AI

401TT-            1 Temperature Transmitter For Tank401                                AI

  STEAM                    Control Valve                                                             AO

Hardware

 Batch Process : summary of hardware,already explained in earlier posts
The di erent hardware used in the Batch Process includes:
1. Tanks
2. Switches and Transmitters
3. Valves
4. DCS (DeltaV)
4.1.1 Tanks


All the tanks are made of stainless steel so to have corrosion free batch process.
The ingredient tanks have the following dimensions.
Overall Length - 950 mm
Diameter of tank- 550 mm
Capacity- 150 litres


The reactor tank has the following dimensions.
Overall Length - 1100 mm
Diameter of tank - 700 mm
Capacity - 350 litre

Batch reactor Instrumentation

Hi Friends,


 up to now i shared structure of batch reactor and instrumentation regarding bottle filling section of batch reactor using B n R PLC.I also shared cable laying for instruments which are required on batch reactor.i am sure you are now waiting for the batch reactor instruments for which we done cable laying.
Here are the instruments which are mounted on batch reactor.


1.Solenoid valves are used to control the inflow into the three ingredient tanks.
These are inch line size and have direct 24V DC electrical actuation. They have
been fi tted to the tanks with appropriate barrel nipple and reducer assembly. 
There are 3 solenoid valves which are mounted on the upper side of 3 tanks for ingredient inflow.
 I want to mention one important thing that cable for these valves comes directly from DCS panel,there is single JB connection for these cables in process lab unlike other Multicore cables.


In case of failure:first check actuating supply to the coil,in our case its 24 V d.c. if not then,follow these steps- 


 a.cable connections,check cable continuity.
 b.If cable continuity is OK,further check 24v dc from card, check also whether     channel is enable or not in DCS.
 c.If 24 v d.c is coming then may doubt on coil.


2.Angle valves with pneumatic actuators are used to control the ingredient 
inflow into the reactor assembly. The actuators are electrically actuated with 230V AC supply controlled through DCS via a relay mechanism. These valves are also 3/4 inch line size and are specially designed to achieve better flow rates.


Cable connections from DCS to B n R panel into TB4 and further it goes to angle valves through relay.24 v dc coming from DCS and through relay 110 v ac or 130 v ac going to the coil depending on its specification.So when coil actuates,it gets magnetized and air supply enter into actuator and valves open.


Troubleshooting procedure same as that explained in angle valve,just check the coil procedure.( whole B n R panel picture should be uploaded soon,so u can check where is TB4 location )


3.Fi ne and coarse valve assembly is tted at the outlet of the reactor tank for bottle lling purpose using appropriate barrel nipple and reducer assembly.Note that these both valves get 24 v dc from b n R panel which is explained earlier.


4.switches and transmitters are mounted on each tank to provide high and
low level alarms for each tank as well as continuous level indication and control for the reactor tank section.these are as follows :



Tank 101: Conductivity Type Level Switch (HL and LL)
Tank 201:Displacer Switch (HL), Magnetic Float Switch (LL)
Tank 301:Capacitive Level Switch (HL), Vibrating Fork Switch (LL),
              Ultrasonic Transmitter for continuous analog level reading.                         
Reactor   :Capacitive Level Transmitter for reactor level measurement

Batch process assembly

Hi Friends,
    Up to now, we made you familiar what we want to do with our lab batch reactor pilot plant.Still we are here mentioning some points regarding process and batch reactor assembly so that we can know how many and which instruments we are using.We know the systems used are Delta v and B & R PLC.So check it process and instruments we are using :




1.The system consists of 4 tanks, three of which contain ingredients A, B and C
   and has a maximum capacity of 150 liters each.
2.The mixing of the three ingredients takes place in the 4th tank which is the         reactor tank. The reactor tank has a capacity of 350 liters. Reactor is provided with an agitator which is actuated by a 3 phase motor.Agitator is for mixing the  ingredients.
3.The reactor tank is surrounded by a steam jacket around its periphery over a
height of 800mm.instruments are in next post