Implementation of S88 Model MIS No.

121416013
M.Tech (2nd Year)
for Batch Processing Pilot Process Instrumentation
College Of Engineering, Pune
Plant
Introduction / Project Overview / Project Idea: For Automation of Continuous, Batch and Discrete Pilot plants, We have three pilot plants that is
Boiler, Batch and Bottle Pilot Plant. Boiler pilot plant, which is the application of continuous process automation. Batch Process pilot plant, which is the
application of batch process automation system and Bottle Filling pilot plant is the application of discrete automation system. All the pilot plants will be
controlled by its own Local PLC's, Two Siemens S7-1200 PLC is used as controller for Batch and Bottle Filling Pilot Plant and Allen-Bradley 1400B is for
Boiler and these are also communicated with higher end controller Controllogix and DeltaV DCS and basic objectives are Implementation of S88 model for
batch processing pilot plant , Implementation of advance control strategies on boiler and heat exchanger and configuration of motion control using S7-1200
PLC.
Needs:
The increasing demands on flexibility and customer-driven production lead to an augmented interest in batch processes, which are more
economical for small-scale production. Furthermore, the growing demands on efficiency and reliability of industrial processes have increased the
importance of the implemented control systems and lead to an extension of their scope. In batch systems, the connection of the recipe and the mechanically
fixed equipment network represents a many-to-many relationship; this provides the flexibility of the batch systems, which leads to a multiproduct and
multipurpose plant. The technological operations follow one another in a predefined order. The equipment is designed not only for producing a single
product but also the same technological unit has to be capable for different operations or to produce different products. Consequently, significantly different
conditions might be necessary, which demand high flexibility from both equipment and control.

Block Diagrams & Results

Fig.2 Communication with higher end

controller
Fig. 3: Class Based Approach

Fig.1 P&ID of Batch Processing Plant

Fig.4 Arbitration for coordination between two phases Fig.5 SCADA of Batch Processing Pilot Plant

Hardware Used Software Used Benefits

Batch Pilot Plant (Siemens Step 7-
1200)
Bottle Filling Pilot Plant (Siemens
Step 7-1200)
Boiler & Heat exchanger Pilot Plant
(Allen-bredaly micrologix 1400B)
ControlLogix 5560
Emerson DeltaV S series
Motors, Actuators, Transmitters,
switches, etc
TIA V11 (Siemens Step 7)
RSLogix 500 and 5000
Factory Talk View Studio
RSLinx Enterprise
DeltaV Operator configure
Control studio
DeltaV Explore
DeltaV Recipe Studio
Batch Operator Interface
Batch Executive
IFIX 5.8 (Local SCADA)
IGS & Kepware(OPC)
MATLAB
It can reduce initial capital outlay (the cost of setting up the machines)
because a single production line can be used to produce several
products.
Batch production can be useful for small businesses who cannot afford
to run continuous production lines.
If a retailer buys a batch of a product that does not sell, then the
producer can cease production without having to sustain huge losses.
Batch production is also useful for a factory that makes seasonal items,
products for which it is difficult to forecast demand, a trial run for
production, or products that have a high profit margin.
Reduce in risk

Name: Abhimanyu Kumar Guide: Prof. S. D. Agashe