Category Archives: Intelligent Automation

Painting spray booths

Use of Programmable Automation Controller in Painting spray booths

Ascon Tecnologic’s PAC (Programmable Automation Controller) has solved the control of sophisticated painting spray booths for the automotive industry. The system assures enhanced tasks such as:

  • Additional air flow, to achieve the required temperature and to avoid dust
  • Heat energy optimization
  • Static electricity Neutralization or reduction
  • Eco function to adjusts airflow and reduce cycle times.
  • Remote monitoring and control functions
Painting spray booths
Painting spray booths

The Ascon Tecnologic solution

The solution can be found by using controllers of microPAC series, Touch screen of OP-MT Series and DY web server to add the remote monitoring and control function. The PAC (Programmable Automation Controller) has been selected as most suitable device to control the most important functions including the management of:

  • Temperature, pressure and other analogue variables
  • Process status and safety devices
  • Control signals to burner and inverters, interlocks commands and alarms.

I/Os are then processed by the CPU, which includes PID and auto tune algorithms, profiles generation, mathematics, sequences and logics to execute typical functions such as normal or eco operation, pre clean, spray, wait, purge, bake, cool down and cleaning. All programmed by standard using an IEC 61131-3 compliant software environment

The DY web server grants quick assistance in case of maintenance allowing, by an internet connection, to upload, microPAC and OP programs, to do changes and to receive e-mails signalling booth or burner fault conditions.

The OP-MT Touch screen has been designed keeping the operator in mind with icons and images to represent actions and functions, on-line help and all the necessary information are always available. RTD temperature sensor completes the system by offering accurate temperature acquisition.

The selected products

The system uses the following Ascon Tecnologic products

Model Description

  • MP-01-22010M0 MicroPAC Programmable Automation Controller with on board I/Os
  • MP-D1/8-8/M0 Expansion module for MicroPAC, 8 digital inputs and 8 digital outputs
  • DY-5121 Web server
  • OP MT8104 Touch Screen Operator Panel
  • ZTR-22D/1P RTD temperature sensor

The advantages

  • Accurate temperature control in accordance to the defined profiles
  • Process time reduction
  • Compact controller with on board I/O, saves space and wiring work
  • Easy management of sequences and logics
  • Complete information available on operator panel
  • Remote connectivity

ADVANCETECH is an authorized distributor for AsconTecnologic. For more information, please visit PLC & PAC

Sigma CanOpen Series

Sigma I/O modules for controlling temperature under extreme ambient conditions in a glass plant

AsconTecnologic’s Sigma I/O modules have been used under extreme ambient conditions to control temperature in a forehearth of a glass plant in Siberia.

The forehearth must grant a thermal process suitable to obtain a defined and stable glass temperature together with thermal homogeneity and stability. Also required is the capability to quickly reach the thermal stability after a job change.

Efficient conditioning depends on the mechanical characteristics of the forehearth and on the heating and cooling systems. Also latest state-of-the-art control systems allow to use the forehearth for a wider range of applications and tonnages.

Sigma ModBus Series
Sigma ModBus Series

The application

The plant typically produces white glass bottles. An end fired furnace feeds a forehearth with two distribution sections and three lines to feed the forming machines. Each distribution section and each line has 2 to 5 zones for a total of 20 zones.

Temperature control of each zone is obtained by heating with gas fired burners or cooling by opening the roof of the forehearth and activating powerful fans.

The homogeneity of the melted glass to each forming machine needs to be monitored by measuring the temperature in three different points at three different levels for a total of 27 temperatures.

The area is subject to the low ambient temperatures, typical of this region, and becomes quickly hot when the glass flows, so the selected instrumentation should be able to sustain extreme temperatures.

AsconTecnologic’s solution

Analogue I/O modules acquire the temperatures to be controlled in each zone of the glass distribution sections and forehearth lines. They also acquire the temperatures of the glass fed to the forming machines and detected by thermocouples directly plunged into the melted glass.

The 2500V insulation of the Sigma I/O modules allows the system to work properly notwithstanding the strong disturbances coming from the furnace electrodes.

Digital I/O modules are used to manage the safety interlocks of the forehearth and the interfaces with the rest of the plant.

ADVANCETECH is an authorized distributor for AsconTecnologic. For more information, please visit http://advancetech.in/plant-automation/acquisition-and-data-recording/io-modules

 

PAC

I/O modules application for Cryogenic gas filling station

Input-output interface provides a method for transferring information between internal storage and external I/O devices. Peripherals connected to a computer need special communication links for interfacing them with the central processing unit.

Ascon Tecnologic’s Sigma I/O modules are used in a plant that loads gas into bottles for transportation. This plant includes a central cryogenic tank, a high pressure pump, a vaporizer and several filling stations. The plant requires controls to be mounted in each location with a really distributed system.

Cryogenic gas filling station
Cryogenic gas filling station

The process uses the controlled low temperature technology that compensates the heating generated by the compression of the gas into the bottles.

Main variables and data to be monitored and controlled to guarantee the correct and safe automatic operation of the plant include:

  • Temperature of the liquefied gas at the pump delivery
  • Temperature of the gas downstream of the vaporizer
  • Temperature of the pump stuffing box
  • Temperature and pressure at the bottles filling

Advantages

The Ascon system and in particular the Sigma I/O modules were preferred thanks to some of their specific characteristics such as:

  • Modules are stand-alone, with built-in Fieldbus interface and power supply thus allowing it to realize a really distributed system
  • Modules are intelligent, thus allowing it to unburden the CPU and increase the connectivity speed
  • Modules are flexible easily configurable as inputs or outputs

ADVANCETECH is an authorized distributor for Ascon Technologic products in India. For more information, please See: Distributed & Remote Controls  and PLC & PAC

 

m1

Waste Management – In-vessel composting system now simplified with M1 Controllers

Composting is a natural process allowing:  reuse of wastes, improvement of productive soils and preventions of environmental degradation.

Large-scale production requires process control to ensure that composting is rapid, uniform, that the product is pathogen free and meeting the standards. The main items to be controlled and monitored are:

  • Quantity of oxygen to get aerobic degradation while minimizing cooling,
  • Temperature to achieve sanitization
  • Feed rate of waste,
  • Mixing of the material,
  • Emissions of odors and hazardous aerosols.

Systems shall accommodate any feedstock or combinations of feedtocks, such as municipal solid wastes and food waste; consequently the control system must be programmable and expandable.

organicFor a large plant in Germany, thirty-eight M1 controllers are used for temperature and O2 acquisition and control while  SigmaPAC  unit CU-02 together with six DM-32TS units, for a total of 192 I/Os, are used to acquire the measurements via MODBUS RTU and manage logic and sequencing functions.

m1

Advancetech is an authorized distributor for ASCON technologic. For more information, please visit http://advancetech.in/plant-automation/control-system-plc-pac/multiloop-controller

wireless

Go Wireless!

Welcome to world of Wireless Technology! In this blog we will understand types of wireless technology and their applications.

There are three types of Wireless technology:

  1. Zigbee
  2. 2.4 GHz based wireless
  3. GSM/GPRS based wireless

wireless

Zigbee based wireless technology

Zigbee is used to create personal area network in 10 to 100 meter line of site connection. In this technology very low power is required. Battery life is long compare to other two. Zigbee is mostly used in home automation where distance is very low. Speed of Zigbee is 250 kbps defined

  • General Applications of Zigbee :
  1. Industrial equipment that requires low rate wireless data transfer
  2. Wireless light switches
  3. Electrical within home displays
  4. Traffic management system
  • Advantages :Simpler and less expensive ,Low power consumption & Easy to install

2.4 gHz based wireless technology

2.4GHz wireless network is used for most of industrial application in which distance is in kilo meters but not more then 3 km. It requires more power to send data than Zigbee. It is work on 2.4 GHz free band in India. This technology can send & receive data up to 3 km with high gain antenna. It must require line of site connectivity.

  • General Application of 2.4 GHz technology
  1. Water level transmitters
  2. Temperature transmitters
  3. Wireless energy monitoring system
  4. Data transmission between to place in plants.
  5. To create a long distance network in plants.
  • Advantages : Long distance communication,No additional cost after installation,Low maintenance cost compare to wired network

GSM/GPRS based wireless technology

This technology is used for very long distance data transmission. In this technology, there is no limitation of distance only requirement of GSM or GPRS network. It can send & receive a data on any network. In GSM/GPRS devices requires internet network to send & receive data from any location

  • General Application of GSM/GPRS technology
  1. Water distribution system over a city or state which can be connected by central location through GSM/GPRS
  2. Send & Receive analog or digital data of industrial plant to central control room
  3. In Tank farm automation
  4. Liquid level transmission in big refineries
  5. Process data transmission in big plants
  • Advantage : No limitation of distance
corrosion

CORROSION MONITORING IN OILFIELD, PIPELINE, AND INDUSTRIAL PROCESSES

corrosion

Safety is the key parameter that every asset manager is concerned of and industries are spending billions of dollars every year through corrosion monitoring and control programs to keep assets  healthy.

There are various corrosion measurement technologies that are available for monitoring industrial process systems. They range from non-direct/non-intrusive to direct/intrusive techniques and include everything from simple corrosion coupons to sophisticated electrochemical techniques. These systems should be selected to meet the specific needs of particular plant requirements to minimize downtime and equipment failures.

Irrespective of this huge spend, failures are still happening, as all the current methods used are more of reactive in nature. They focus on detecting if failure has happened or not whereas ideal way is to have solution that can help in predicting failure so that appropriate action can be taken before failure.

CEION SENSORS from Teledyne Cormon has Patented technology for high resolution metal Loss.These are based on ER Principles. Metal loss measurement resolution better than 100 times that of conventional ER probes is possible. It Incorporates: Analog Electronics, DSP Software element design.

It can be used for erosion/corrosion. It is used in probes and spools, topside and Subsea.