Process Industry: Boiler Operation & Data logging

Boiler: In a process industry, a boiler is primarily used to generate steam, which is then utilized to provide heat for various stages of the manufacturing process, including heating liquids, sterilization, drying, and powering machinery, playing a critical role in maintaining precise temperatures needed for consistent product quality across different industrial sectors like food processing, chemical manufacturing, and textiles.

Case Study Process Industry
Applicable Industry food processing, chemical manufacturing, and textiles
Use Case Boiler Operation & Data logging
Interfaces PLC, SCADA System, Sensor, field instruments with cabling
Customer Leading Captive Energy Sectors
Data Exchanged Data logging in Excel format
Technology PLC with SCADA
System PLC Automation system
Challenges:
  • old relay base control panel
  • Low efficiency
  • Frequent shutdown due to failure of components
  • Long repair cycle becouse of old tech instrumentation
  • Difficult to expansion
  • Requires a lot of switchboard space
  • Installation is very labor intensive
  • Trouble shooting is extremely difficult
  • Modifications to the control functionality are complicated and seriously tedious.
Solution:

We as VACPL provided efficient and end to end solution of PLC based control panel and which is helping customer in below ways. installation time is greatly reduced with PLC control systems due to the reduced amount of hard wiring required. In other words, we only need to hard wire the input and output devices. The control logic is implemented using software not hard wired relays.

Modifications to the control logic can easily be done using software to modify the ladder logic program rather than hardware and wiring modifications that would normally be the case with relay logic control. The same PLC can be used for a wide range of control system applications.

Impact 1
  • Batch time reduced by 15%, hence increase in productivity.
  • Precise evaporation ratio.
  • No loss of energy since steam is not required to be released through bypass valve Improvement in product quality
Impact 2
  • Efficiency improvement.
  • Down time reduction.
  • Proactive maintenance.
  • Cost reduction of overall maintenance.