NOTICE: BE Instrumentation (SEM-VII)

Date: 01/10/14.

FORMAT FOR SYNOPSIS

General instructions:

1) Paper:
A4 size, white bond paper
2) Typing:
Font size: 12 points
Font: New Times Roman, Arial, Verdana
Spacing: 1.5 lines
Margins: left-1.5, right-1, top-1.2, bottom-1
Chapter numbers& titles: 14 point font/ bold/Center justified.
Sub titles: 12 point font/ bold/Center justified.
3) Number of copies to be submitted: 02
4) Binding: Spiral binding with plastic sheet on both sides. Top sheet must be
transparent.
5) Sequence:

Title sheet,

Certificate,

Summary sheet,

Contents sheet, List of Figures

Chapter 1.

References,

Appendixes

@ The chapters contents should include- (start page numbers here onwards)

Chapter 1 Definition of project,

Chapter 2 Review of literature,
Chapter 3 Working Principle and Block diagram
Chapter 4 Work Done, Approximate Cost of Project,
Chapter 5 Future work (for SEM-VIII)

6) Numbering system:

Chapters will be numbered as Chapter 1, Chapter 2, etc.

Sections are numbered by decimal type notation e.g. 3.2 refers to section of
chapter 3 & 3.2.1 refers to subsection of section of section 2 of chapter 3.

Figures & equations must be numbered by using decimal type notation.

Title sheet, Approval sheet will not be numbered.

Page numbers should be typed on top right corner.

7) Date of Presentation: 7th & 8th October14.

Date of Synopsis submission: 27th October14.

8) Project Oral: Saturday 01/11/2014

First Page: Title sheet

TANK LEVEL CONTROL USING PLC AND ROTARY DRYER FURNACE

(In capital letters)

Synopsis
Submitted in partial fulfillment of the requirements
For the degree of

BACHELOR OF ENGINEERING

By

VIVEK KUMAR SINGH

NILESH HANSKAR

SANKALP BAGWALE

Under the guidance of

Prof. SUSHMA WANKHEDE

DEPARTMENT OF INSTRUMENTATION OF ENGINEERING

Bharati Vidyapeeth College of Engineering, Navi-Mumbai.
University of Mumbai.

Second page: Approval sheet

Bharati Vidyapeeth College of Engineering, Navi Mumbai.

Department of Instrumentation Engineering

Certificate of Approval

This is to approve that Project entitled TANK LEVEL CONTROL USING PLC AND
ROTARY DRYER FURNACE

and

The synopsis of the project is submitted by

VIVEK KUMAR SINGH

NILESH HANSKAR

SANKALP BAGWALE

in the partial fulfillment of the degree of B. E. Instrumentation Engineering.

(Name & Signature of Guide &

Internal Examiner)

(Name & Signature of HOD)

Date:

(Name & Signature of External Examiner)

Date:

Third page of the synopsis: summary sheet.

1. Name of the Students

:VIVEK KUMAR SINGH

NILESH HANSKAR
SANKALP BAGWALE

2. Class and Semester

: BE.IS 7th SEMESTER

3. Title of the Project

: TANK LEVEL CONTROL USING PLC AND

ROTORY DRYER FURNACE

4. Name of Internal Guide

: Prof.SUSHMA WANKHEDE

5. Name of the Company and External Guide

(If applicable)

:Bhabha Atomic Research Center,

Ms.Kalpana Mitra

6. Abstract

When Uranium is heated to its melting point,magnitio thermic reduction furnace(MTR)

is heated.In this UF4 is in powdered form.Uranium converts it into metal form and
UF4 is heated to its melting point(1200 c -1500 c).In MTR there is a lining material
of MgF2 because while heating MTR it should have bearing capacity.
Now we obtain MgF2+F2+Uranium .Now as uranium starts melting,the waste
material is in powdered form.This powdered form content is mixed with nitric acid.In
this process uraninium gets dissolved in nitric acid,but magnesium doesnt get
dissolved.So this solution is filtered out .After filteration uranium gets seperated from
nitric acid,but some of the contents of the uranium particles which do not get
seperated are still present in nitric acid solution.The magnesium particles are sent
back and this magnesium is reused and moistured content is processed in rotary
dryer furnace.In this the moisture is removed from the content by heating process
and again sent back for reusing it the remaining content of Magnesium
Flouride(MgF2).

Page-4: Index

Page-5: List of Figures (if any)

Page-6: List of tables (if any)

Chapter 1 Definition of project

Rotary Dryer is a batch process used for drying powdered feed

material.
It works on Indirect Heating Principle.
Feed material is passed along the furnace using screw conveyer.

Review of Literature

In Rotary Dryer Plant MgF4 is used as a feed material in wet powdered

form.
MgF4 is passed along the furnace using screw conveyer.
Rotary drum is rotated using VFD controlled motors.
Heating is done by using high resistance coil.
Current flow through the coil is controlled by Thyristor.
Furnace is heated up to 300-500C.
Temperature is measured by a Thermocouple.
Blind controller is used for safety purpose to avoid excess temperature
(700C).
Exhaust gases is passed through a bag filter for removal of any residue.
Solenoid operated Butterfly Valve is used in prior to bag filter to avoid
damage to bag filter due to high temperature of the gas
Exhaust gases is then escorted out by using Blower.

Working Principle

Wet material goes into the feeding hopper by belt conveyor or bucket
elevator, then through the feeder goes into the feed pipe. The feed
pipe slope is greater than the natural inclination of the materials, so
that the material can inflow the rotary dryer smoothly.
There is one hot air furnace supply the hot flue gas for the rotary dryer
usually. The fuel can be waste wood, coal, natural gas, diesel, etc.
The rotary dryer cylinder is tilted slightly compared with horizontal.
Materials and hot flue gas goes into the rotary dryer cilinder from the
higher end. During the rotation of the cylinder, the material by gravity
goes into the lower end. When the wet material is in the process of
moving forward in the rotary dryer cylinder body, the lifting plates
inside the rotary dryer cilinder makes the material up and down to
contact with the hot flue gas completely. Thus, the moisture inside the
wet material is evaporated into water vapour, and finally we get the
dried materials.At the end of the rotary dryer, using one belt conveyor
to transport the dried material into trucks or storage room directly.

PROCESS INSTRUMENTATION DIAGRAM

Block Diagram

Work Done

Helped in installation and testing of various components

namelyTemperature Sensors (TE)- Thermocouple (Type-k).
Temperature Indicator and Controller (TIC).
PID Controller.
Solenoid operated Butterfly Valve.
Differential Pressure Transmitter (DPT).
Variable Frequency Drives (VFD).
Air Ingress Valve (AIV).
Resistive Heating Using Thyristor.

Future Work

Installation and Testing of components for Tank Level Control.

PLC programming for Tank Level Control.

Diffrential Pressure Transmitter

Key Specifications

- Ranges from -100/+100 Pa to -10000/+10000 Pa (according to

models) - Configurable intermediary ranges
- 0-10 V or 4-20 mA output, active, power supply 24 Vac/Vdc (3-4
wires) or 4-20 mA output, passive loop, power supply from 16 to 30
Vdc (2 wires)
-

ABS V0 housing, IP65, with or without display

14 turn system mounting with wall-mount plate
Housing with simplified mounting system
Solenoid valve for auto-calibration (only on CP111 model)

TECHNICAL FEATURES
Accuracy
CP111 : 1% of reading 2 Pa ; CP112 : 1.5% of reading 3 Pa ;
CP113 : 1.5% of reading 3 mmH2O 1 Pa ; 0.1 mmH2O ; 0.01
mbar ; 0.01 inWG ; 0.01 mmHG ; 0.1 daPa ; 0.001 kPa
Type of fluid
Air and neutral gases
From 0 to +50 C
Measurement units
Pa, mmH2O, inWG, mmHG, daPa, kPa, hPa, mbar

Response Time
1/e (63%) 0.3 s
Autozero
Manual with push-button ; Automatic by solenoid valve (only on CP111
model)
Overpressure tolerated
CP111/112 : 21 000 Pa CP113 : 69 000 Pa
Storage
From -10
temperatur
to +70 C
e
Solenoid Valves:
Butterfly valves with pneumatic actuators shall be provided with 5/2
solenoid valves of repute make like ROTEX / HERION. The solenoid
valves with duly connected stainless steel piping to the actuators shall
be suitably mounted on the actuators. The specification for solenoid
valves is as under:
Service fluid:
Normal operating air pressure 4.0 kg/cm2g and 600C Maximum
operating air pressure 7.0 kg/cm2g.

Power supply: 24 V DC
Line size: 14 inch. NB
Material of construction of valve body shall be aluminum or its
alloy. The valve seat shall be made up of soft material like
Teflon/Viton so as to provide tight shut off.
The solenoid valve shall have threaded 14 NPT (IF) ports as per
ANSI B 2.1/2.2.
The solenoid valve shall be suitable to be mounted on the
actuator with suitable bracket and tubed to actuator air in let
with stainless steel tubing.

 The coil shall be of resin-molded construction. The insulation

between either lead of the coil and the housing shall be better
than 100 M-ohm at 100 V DC at ambient conditions.
The solenoid valve shall have terminals for connection to internal
circuitry. Terminals shall be suitable for 2.5 mm2 cables.
The solenoid valve should not have a time delay of more than
100 milliseconds between energisation and actual operation. Coil
current shall not be more than 250 mA at operating Voltage.