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Automation of VBF A and B

The document describes automating the vacuum belt filter (VBF) process at a CAN plant using a PLC. The VBF uses a 4-stage counter current washing process to separate lime, AN solution, and CAN slurry. The existing hard-wired relay logic system controlling the VBF valves and timers was problematic. The new solution implements a PLC, HMI, soft timers, and 24VDC circuitry for inherently safer design and reduced maintenance compared to the 220VAC system. An alarm management system was also added to monitor the VBF process.

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Abdul Moeez Ali
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79 views15 pages

Automation of VBF A and B

The document describes automating the vacuum belt filter (VBF) process at a CAN plant using a PLC. The VBF uses a 4-stage counter current washing process to separate lime, AN solution, and CAN slurry. The existing hard-wired relay logic system controlling the VBF valves and timers was problematic. The new solution implements a PLC, HMI, soft timers, and 24VDC circuitry for inherently safer design and reduced maintenance compared to the 220VAC system. An alarm management system was also added to monitor the VBF process.

Uploaded by

Abdul Moeez Ali
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 15

Automation of Vacuum Belt Filter A

with PLC at CAN Plant

1
Vacuum Belt Filter

Plant: CAN

Section: CN

Make: Pannevis

Operation: Mechanical separation

Purpose: Separation of Lime and AN

solution from CAN slurry.

Method: 4-Stage Counter Current

Washing
2
VBF Cycle

The filter cloth rolls non-stop

3
CAN Slurry Feed
Blue dots: AN
Yellow dots: Lime

Vacuum Valves Open & Air Valves Close


4
CAN

𝞓P

Transport cylinder de-pressurizes and


moves tray forward

AN solution is filtered
5
Vacuum Valves Close & Air Valves Open
6
Transport cylinder pressurizes and pulls tray backward

7
Algorithm
Back Proxy Switch operates
Cylinder de-pressurizes
Tray moves forward

Cylinder pressurizes Vacuum Valves Open


Tray moves backward Air Valves Close

Filtration

Front Proxy Switch operates


Vacuum Valves Close
Air Valves Open 8
Existing System

Hard-wired Relay logic based on 220 VAC.

Enclosure of SOVs and 5/2 Valves Enclosure of Timers


9
Problems & Challenges
Frequent Valves Troubleshooting

No Alarm Management System

VBF Timers, Relays & SOVs Malfunctioning

220 VAC High Voltage

Consumption of Manhours
(Approx. 210 Hrs/Yr)
10
Aim of the Project

Technology
Inherently Safer
compliant with
Design
IEC Standards

Minimum Equipment &


Operator GOALS Operational
Intervention Reliability

Reduction in
HSE Compliance
CM Expenses

11
Solution through Automation

Open/Close
Graphical HMI Feedback for
Valves
PLC

Alarm
Management
Soft Timers
System

24 VDC Circuitry 12
System Topology

Control Room

Position
SOVs Switch
Boxes Proxy
Switches
13
Hardware Selection

GE Versamax Micro PLC


Model No: IC200UDR005
I/O Summary

DI DO
Flowserve PMV WS/WM Series
UltraSwitch Switch box 26 5
AI I/O
Model No: PNWS2RPU2PE15 AO
0 0

Weintek HMI
Model No: MT8102

14
Alarm Management System

Delay in opening/closing of Vacuum/Air valves

Vacuum/Air valve stuck

Both proximity switches operate simultaneously

Delay in tray movement

Motor running feedback not received

15

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