Automation and control of the thermal mixing process

Abstract

In this research, the automation and control of an industrial mixing process were developed. Process safety was established through pipeline maintenance, plant instrumentation repair, and the addition of required instrumentation to ensure process safety. The process operation was divided into the industrial operation stages A1,F1, F2, F3, F5, and D1 of the GEMMA guide, designed in the GRAFCET methodology. The design of the temperature and level controllers was carried out using the approximation technique of each closed-loop system to a second order system with zero, based on the pole approximation technique. The industrial process was carried out with the DCS Honeywell HC900, integrating the automation of the system and the temperature and level controllers designed. A real-time SCADA supervision system was implemented to visualize the process and report alarms caused by failures in sensors or actuators. The mixing process was carried out in real-time, evidencing the settling times and overshoot values under the desired conditions.