CPAE PROCESS AUTOMATION INDEX. 2 Brands of PLCs (Keyence & AB) 1 Brands of SCADA (Wonderware Intouch) Pneumatics & Field Instruments

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1 CPAE INDEX 2 Brands of PLCs (Keyence & AB) 1 Brands of SCADA (Wonderware Intouch) Pneumatics & Field Instruments PROCESS AUTOMATION Distillation Column Superheated Steam Generator Centrifugal Compressor Centrifugal Pump Heat Exchanger Flash Drum Gas Turbine Furnace Evaporator CSTR Plug Flow Reactor Fixed Bed Reactor Cogeneration Boiler

2 COURSE CONTENT BASIC AUTOMATION INTRODUCTION AND HARDWIRE RELAY LOGIC DEVELOPMENT Basic Introduction & Evolution of automation Discussion about automation in industry History of automation Futures and application of automation Automation tools explanation Basic hardwire relay logic development & real time practice Automation HEART DEVICE control of relay concept Electrical concept of hardwire relay logic development Live practice on hardwire logic in relay panel Assignment based on digital logic and Boolean equations using relay Introduction of PLC architecture and input / output system in various industries General block diagram of PLC architecture Explain input / output field instrument in industries Explain various standard PLC and software used in industries Explain various PLC programming method used in industries Derive the ladder logic program using hard wire relay logic concept Digital logics gates & Boolean concept Flip-flops & latching concepts in ladder Programming based on k-map rules Assignment based on real time applications

3 PLC PROGRAMMING DEVELOPMENT AND CONTROLS PANEL ERECTION & COMMISSIONING TROUBLESHOOTING USING KEYENCE & OMRON PLC KEYENCE PLC Introduction of Keyence PLC software [ladder builder] and addressing of Input / output system Specification and features of Keyence PLC Addressing of input / output system and memory mapping Live practice on Keyence PLC programming tools software [ ladder builder ] Assignment based on real time applications Explain the application of timer [delay function] in automation industries Explain the role of timer in industries Various type of timer and its application Programming based on timer and live practice in Keyence PLC software Assignment based on timer applications Explain the usage of counter function in automation industries Differentiate the timer & counter function in PLC software and its usage Various type counter and its application Programming based on timer / counter and live practice in Keyence PLC software Assignment based on counter applications Upload / download the program and online monitoring in Keyence PLC panel Communication detail between Keyence PLC and programming tool software in PC Procedure of upload / download the program in Keyence PLC Online monitoring and practice of programming tools software in Keyence PLC panel Assignment based on Keyence PLC series and its evolution Industrial standard of PLC panel Erection, commissioning & Trouble Shooting Basic requirement of PLC panel designing and its apparatus tools Draw the electrical wiring diagram of Keyence PLC panel and trouble shooting Explain the [ source/sink ] type of digital input /output Assignment based on electrical wiring on PLC panel used in industrial application

4 Live practice on PLC panel wiring and application development Examining the field input devices to PLC panel Verifying the field output devices from the PLC panel Design and development of real time industrial projects Assignment based on complete PLC project solution AB PLC: Industrial & Evolution of AB PLC and its programming tool software practice Evolution and specification of AB PLC Addressing Input / Output and memory mapping in AB PLC Working in AB PLC programming tools software Configuration of timer & counter and its application practice Live practice on AB PLC panel explain Special Instruction sets & application development Draw the electrical wiring diagram of AB PLC panel and troubleshooting Practice on special instrument in AB PLC programming tool software Procedure of upload / download and communication details between AB PLC panel and programming tools software Assignment based on real time application development in AB PLC panel Overview of Industrial Field Instrument and explain field pneumatic control System Evolution of analog control system in industry Explain pneumatic control system and its application usage in industry Tools requirement of pneumatic control system and erection and commissioning Connection between pneumatic field device to AB PLC panel and its configuration Live practice on pneumatic control application using level control system (PID control Algorithm) Configuration of analog Input / Output module in AB PLC panel Explain discrete of continuous control method used in level control system Describe PID control algorithm and its configuration in AB PLC panel Live demo on tank level control system interface with AB PLC panel and practice

5 Special input module configuration (RTD, Thermocouple) in AB PLC and its real time application development and practice Explain various temperature measuring instrument in industry and its feature Configuration of special Input module [RTD, Thermocouple] in AB PLC panel Explain temperature controlling method in industry and its application development in AB PLC panel Assignment based on temperature control loop in AB PLC panel and SCADA design in Wonderware INTOUCH Interfacing of operation work station in AB PLC with SCADA Wonderware INTOUCH and application development Interfacing between AB PLC and Wonderware INTOUCH and its drives configuration and addressing Live practice and online testing of tag signal in Wonderware INTOUCH to AB PLC panel Designing of operator workstation in Wonderware INTOUCH SCADA for tank level control system and temperature control loop in industry Assignment based on continuous process application in industry LIVE INDUSTRIAL PROJECT Level / Temperature / Pressure Process Control Using AB PLC Feed Forward Method Feed Back Method Cascade Ratio INTOUCH SCADA Introduction of Wonderware INTOUCH SCADA system & design the industrial Application development Introduction of Wonderware INTOUCH SCADA system and its live demo application Create tag name & data base and graphical object properties Explain real time PLC I/O drive and configuration Assignment based on application design

6 Historical & real time trends monitoring and alarm events configuration Explain alarm event configuration Explain real time trend display Explain historical display configuration Assignment based historical display application SCADA script programming and ODBC [using MS-ACCESS] & DDE [using MS-EXCEL] Connectivity in INTOUCH SCADA Explain SCADA script programming Explain DDE [Dynamic Data Exchange using MS-EXCEL] connectivity Explain ODBC [Open Database Connectivity MS-ACCESS] connectivity Assignment based on DDE & ODBC connectivity Recipe management and I/O drive configuration Explain recipe management system and configuration Live practice & assignment based on recipe management system I/O drive configuration and its procedure Various example of industrial application using recipe management system Interfacing of AB PLC panel to Wonderware INTOUCH SCADA SYSTEM Communication parameter setting between AB PLC and Wonderware INTOUCH AB PLC input /output and memory mapping for real time tag creation in Wonderware INTOUCH Communication cable details and protocol information Assignment based on industrial application Live project development and practice on AB PLC & Wonderware INTOUCH SCADA SYSTEM Explain various project used in AB PLC Explain how to make project documentation Live project development and practice

7 PROCESS AUTOMATION DISTILLATION COLUMN To teach trainees the operating fundamentals of a distillation system To provide opportunity in identifying the main equipments associated with distillation systems. To describe the operation of Depropanizer column. To learn about the startup and shutdown process. To respond safely and efficiently for disturbances and malfunctions in the process. To understand how temperature and pressure affect the operation of a distillation tower. Depropanizer Feed Flow Controller Depropanizer Reflux Feed Flow Controller Depropanizer Top Product Feed Flow Controller Depropanizer Level Controller Reflux Drum Level Controller Depropanizer Pressure Controller Depropanizer Bottom Temperature Control Change in Depropanizer Feed Flow Change in Feed Composition Change in Feed Temperature Change in Reboiler Steam Flow Change in Depropanizer Pressure Change in Depropanizer Reflux Flow

8 SUPERHEATED STEAM GENERATOR To teach trainees the operating fundamentals of a Superheated Steam Generator. To describe about the operation of Boiler To learn about the startup and shutdown process To respond safely and efficiently for disturbances and malfunctions in the process To know how temperature and pressure affect the operation of Superheated Steam Generator. Feed Drum Level Controller Deaerator Pressure Controller Deaerator Level Controller Three Element Boiler Control Change in FG and FO supply Pressure Change in Steam header Pressure Boiler Feed Water Supply ( to Deaerator ) Pump failure Boiler Feed Water Supply ( to Steam Drum ) Pump failure Water Supply ( from mud drum to steam drum ) Pump failure

9 CENTRIFUGAL COMPRESSOR To teach trainees and to recognize understand the operating fundamentals of a Compressor. To describe about the operation of Compressor. To learn about the startup and shutdown of the process using documented procedures. To respond safely and efficiently to disturbances and malfunctions in the process. Important control scheme available in this unit is Anti-surge controller which creates a spill back from the outlet of the compressor to the inlet to avoid compressor surge. Feed Gas Failure Compressor Failure Fail Cooling water supply Change in Feed Gas Temperature Change in Molecular weight Change in Feed Supply Pressure Change in Compressor RPM

10 CENTRIFUGAL PUMP To teach trainees the operating fundamentals of a Centrifugal Pump. To create a virtual environment for the trainees to understand various functional aspects of the equipment, normal operating conditions. To learn about the changes in the input parameters and their corresponding response in the output. To respond safely and efficiently for disturbances and malfunctions in the process Feed Water Level Controller in the Drum Minimum Recirculation Line flow Controller Change in Vapour Pressure of feed Change in Specific Gravity of Feed Change in Pump RPM Change in Discharge of Pump to Head Change in Pressure of the Tank on Head

11 HEAT EXCHANGER To teach trainees the operating fundamentals of a heat exchanger To portray all the design parameters and variation of them with respect to process conditions. The Temperature Controller to maintain the hot fluid outlet temperature of the heat exchanger Change in type of Cold and Hot fluid (Deg API & Boiling Point) Change in Inlet Temperature ( Cold and Hot side) Change in Dirt factor ( Cold and Hot side) Change in Specific Gravity ( Cold and Hot side) Change in Inner Diameter ( Shell and Tube side) Change in Baffle Spacing (Shell and Tube side) Change in Number of passes ( Shell and Tube side) Change in Tube Pitch Change in Length of Tube Change in Number of Tubes Change in Flow area per Tube Change in Surface Area per Linear Length

12 FLASH DRUM To teach the trainees the operating fundamentals of the Flash drum. To create a virtual environment for the trainees to understand various functional aspects of the equipment, normal operating conditions. To learn about the changes in the input parameters and their corresponding response in the output and design. A Pressure controller is used to maintain the Flash drum pressure. A Level Controller to maintain the level of the Flash Drum. Change in Inlet feed flow rate Change in feed composition

13 GAS TURBINE To teach trainees the operating fundamentals of a gas turbine system. To provide opportunity in identifying the main equipments associated with gas turbine. To learn about the startup and shutdown process To respond safely and efficiently for disturbances and malfunctions in the process. To understand how temperature and pressure affect the operation of a gas turbine unit. Load Speed Controller to maintain the speed of the governor in power transmission unit. Steam Temperature Controller in Desuperheater. Steam Flow Controller in Desuperheater. Water Level Controller in Steam Drum. Change in Ambient Temperature Change in GT Oil and Gas supply Pressure Change in Grid KV and Frequency Change in Feed water supply Pressure and Temperature HRSG Fuel Burner failure Lube Oil pump trips Diesel Engine Starter failure GT Fuel Burner failure Circuit Breaker and Exciter failure

14 FURNACE To teach trainees the operating fundamentals of a heater. To portray all the design parameters and variation of them with respect to process conditions. To respond safely and efficiently to disturbances and malfunctions in the process Furnace outlet Temperature Controller Fuel Gas Supply Pressure Controller Air Supply Hand Controller Change in Feed Gas Temperature Change in Feed flow Change in Fuel Gas Calorific Value

15 EVAPORATOR To teach the students about various operating fundamentals and the design of an Evaporator. To create a virtual environment for the trainees to understand various functional aspects of the equipment, normal operating conditions. To learn about the changes in the input parameters and their corresponding response in the output and design. A Temperature Controller is used to regulate the flow of steam depending upon the temperature of the outlet sugar syrup. A Pressure Controller is used to regulate the flow of vapor generation. A Hand Controller is used to increase or decrease the feed flow. Change in Feed Inlet temperature Change in Feed flow rate Change in Inner Diameter (ID) Change in Outer Diameter (OD) Change in Tube Pitch Change in Number of Tubes Change in Number of Passes Change in Length of the Tube Change in Flow Area per Tube

16 CSTR To teach trainees the operating fundamentals of a Continuous Stirred Tank Reactor To create a virtual environment for the trainees to understand various functional aspects of the equipment, normal operating conditions. To learn about the startup and shutdown process. To learn about the changes in the input parameters and their corresponding response in the output. To respond safely and efficiently for disturbances and malfunctions in the process Reactor Temperature Controller Reactor Level Controller Reactant A supply Hand Controller Reactant B supply Hand Controller Change in Inlet Pressure of Reactor Change in Cooling Water Supply Change in Order of reaction Change in feed inlet temperature Change in feed flow ( A & B)

17 PLUG FLOW REACTOR To teach trainees the operating fundamentals of a Plug Flow Reactor. To provide opportunity in identifying the main equipments associated with Plug Flow Reactor To learn about the startup and shutdown process To respond safely and efficiently for disturbances and malfunctions in the process Change in Conversion (Adiabatic) Change in Order of the reaction (Isothermal) Change in Feed Flow Rate (Isothermal) Change in Inlet Temperature (Adiabatic and Isothermal) Change in Initial Concentration (Adiabatic and Isothermal)

18 FIXED BED REACTOR To teach trainees the operating fundamentals of a Fixed Bed Reactor. To provide opportunity in identifying the main equipments associated with Fixed Bed Reactor To respond safely and efficiently for disturbances and malfunctions in the process Two Temperature Controllers to maintain the Bed Temperature Change in Hydrogen Flow Change in Catalyst Activity Change in Feed inlet Temperature COGENERATION BOILER To teach trainees the operating fundamentals of a Co Generation Boiler To learn about the startup and shutdown process To respond safely and efficiently for disturbances and malfunctions in the process To know how temperature and pressure affect the operation of Co-Generation Boiler Feed Drum Level Controller Deaerator Pressure Controller Deaerator Level Controller Three Element Boiler Control

19 Change in FG and FO supply Pressure Change in Steam header Pressure Boiler Feed Water Supply ( to Deaerator ) Pump failure Boiler Feed Water Supply ( to Steam Drum ) Pump failure Water Supply (from mud drum to steam drum) Pump failure