Introduction

For more than 5 decades Electrosteel has made a name for itself in manufacturing Steel Spun pipes which are used for Civilian Water works across the country. Electrosteel was born in as Dalmia Iron and Steel Ltd. in 1955, at Khardah near Kolkata, which later on became Electrosteel castings Ltd. In 1959 the Cast iron spun pipe plant started at Khardah. In 1982 Electrosteel acquired Shakti pipes at Elavur near Chennai to augment Cast Iron spun pipe production capacity At present Electrosteel have 3 plants at Khardah, Elavur and at Haldia. With a global ambition electrosteel has now spread its wings in more than 35 countries across 5 continents exporting ductile iron pipe and fittings. Electrosteel is Indias market leader in ductile iron pipe line systems with one overriding aim: to be the first choice. Electrosteel is the pioneer to set up a ductile iron pipe plant in 1994 at khardah. Electrosteel has almost modern ductile iron pipe plant at Khardah having a production capacity of 3,00,000 MT per annum having its own blast furnace and captive power plant. This facility also includes a modern in house ductile iron fittings plant using the latest Lost Foam process. Electrosteel has achieved complete process integration, having its own coal and iron ore mines. In a supporting industrial unit at Haldia it has a coke oven, sponge iron plant and a 12MW power plant which help to lower the input cost. Electrosteel employs latest state of the art technology and management concepts to achieve Quality Right the first time. Apart from having ISO 9001 and ISO 14001 certification, companys quality system and products are also approved by agencies like DVGW(Germany), KITEMARK(BSI,UK) and many other Governmental approvals of the middle east. Electrosteel has to its distinction many pioneering firsts: First to set up a ductile iron pipe plant in India First to manufacture Grinding media in India First to introduce Hi-chrome technology to India for cement plant ball mills internals. It has been a pioneer in the manufacture of alloy steel castings in India.

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Brief history of Electrosteel:

Milestones of Electrosteel Castings: 1994: Set up 60000 TPA Ductile Iron Pipe Plant at Khardah near Kolkata, the first ever in India 1995: Accredited with ISO 9002 from Indian Register Quality System an Accredited body of Raad Voor de Certificate of Netherlands for our ductile Iron pipes. 1996: The Company obtained Kitemark license from British Standard Institute (BSI) for its Dl pipes as per ISO 2531, BS EN 545, and BS EN 598.The Company commissioned its own mini-blast furnace with matching capacity for better quality control. 1999: The Company received the ISO-9002 accreditation from BSI for Dl pipes and fittings. 2000: The Company increased its capacity to 120,000 TPA for Dl pipes.The Company obtained Kitemark license from BSI, UK for Dl fittings made at its facilities in Elavur, Chennai as per ISO 2531, BS EN 545, and BS EN 598. Page|2

 2001: The Company scaled its Dl pipe capacity from 120,000 TPA to 150,000 TPA. Mini Blast Furnace capacity increased from 1, 09,000 TPA to 2, 00,000 TPA. 2002: The Company acquired 46% stake in Lanco Industries Limited in March 2002, which is involved in manufacturing of DI Pipes, Pig Iron, Cement and Castings. 2003: The Company increased its Dl pipe manufacturing capacity from 1,50,000 TPA to 200,000 TPA. The Company also received BSI Kitemark license for Dl Fittings at Khardah works, West Bengal. 2005: The Company raised USD 40 Million through the issue of Global Depository Receipts (GDRs) in October 2005 and become the first Indian Company to be listed on Professional Securities Market (PSM) of the London Stock Exchange (LSE) in addition to being the first Company to issue GDRs on the PSM. The Company was accorded Three Star Export House by the JDGFT, Ministry of Commerce and Industry of the Government of India. 2006: The Company increased its Dl pipe manufacturing capacity from 2,00,000 TPA to 2,50,000 TPA and commissioned Coke Oven Plant at Haldia. The Company commissioned 12 MW Power Plant & 30,000 TPA second Kiln Sponge Iron Plant at Haldia. Mini Blast Furnace capacity increased from 2, 00,000 TPA to 2, 35,000 TPA. The Company successfully commissioned Pulverized Coal Injection System in Blast Furnace and Stamp. Charging System in Coke Oven Plant at Haldia, which enhanced operational efficiency. We have been allotted an Iron ore mine at Kodolibad, Jharkhand and a non coking coal mine in joint venture at North Dhadhu. 2007: Implemented SAP ERP system hosted in state of the art 1000 square feet Data center connecting all manufacturing plants and sales offices across Indian Geography supporting 350 user base to enable supply chain of the Company. 2008: Tied up US$ 77.50 mn through ECB, commissioned 360,000 TPA sinter plant at Khardah and commissioned a 75,000 TPA coke oven battery at Haldia. 2009: Commissioned fourth coke oven battery resulting in additional capacity of 70,000 TPA of coke, taking the total capacity enhanced to 280,000 TPA and 250,000 TPA respectively

Main products of Electrosteel Castings:

Ductile iron pipe Ductile iron fittings Ductile iron flanged pipes Page|3

Khardah works at night

Ductile iron pipe:

Ductile Iron (also known as Spheroidal graphite iron or Nodular Cast Iron) was invented in 1949. Ductile Iron retains the corrosion resistance of cast iron but has more than double the tensile strength [Cast Iron- 180 MPa (min), Ductile Iron - 420 MPa (min)]. The essential differences between Ductile and Cast Iron lie in the shape of the graphite in the microstructure of the metal. In Cast Iron, the graphite is present in plate-like flakes, which makes Cast Iron brittle. But in Ductile iron, the shape of the graphite becomes a spheroid nodule, which offers better mechanical properties and makes Ductile Iron sturdy, structurally stronger and shock-proof. Ductile Iron pipe is considered as the most preferred pipe material for water supply and pressure sewerage application all over the world. It offers higher Tensile Strength than Mild Steel and retains the inherent corrosion resistance of cast iron. Pipes made from Ductile Cast Iron, provides substantial benefits in terms of pressure bearing ability, impact resistance and capacity to sustain external static/ dynamic loading.

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Properties of ductile iron pipe:

Properties Tensile strength Elongation at break Elastic coefficient Modulus of elasticity Hardness Density Beam strength Crush load and impact load Bursting strength (min)

Ductile Iron Pipe Min. 420Mpa 10% 1.7104 Kg/mm2 1.71010 Kg/M2 Max 230BHN 7050 Kg/M3 Over 50 Kg/m3 Can take up huge impulse load(Charpy over 0.713) Factor against bursting is 8 to 10

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Diagrammatic presentation of production of Ductile Iron Pipe:

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Fundamentals of Instrumentation
Instrumentation is a composite word, derived from Instrument and Automation. Hence conceptions on Instrument as well as Automation are both equally required to understand the subject Instrumentation.

Instrument:
Any device which can indicate the characteristic status of constituent for any phenomenon is called instrument. It is normally understood by Meter means measuring device. The constitute is known as parameter where as the phenomenon is known as Process.

Automation:
Creation of self spontaneous system as per pre-defined requirements is called Automation. It is normally understood by Automatic.So the Subject of Instrumentation is can be defined as Achievement of Automatic Process or System by using Measuring Devices.

Basic Conception on Measuring Parameters:

1. Parameters: It is the constituents of any phenomenon whether it may vary or may not vary with respect to time. The age of any person is a varying parameter which is continually changing at every moment. The study syllabus for a particular branch is changing at every semester. In these cases Age, Syllabus. Area are the examples of parameters. The constituent of any phenomenon of any phenomenon can be classified under the following types of parameters:a. Physical Parameters:

Means the character of the parameter is physical in nature like Age, length, area, pressure, level, flow etc.
b. Analytical Parameters:

Means the character of the parameter is composition or chemical in nature like PH, conductivity, % parts of a mixture or compound etc.
c. Special Parameters:

Means the character of the parameter is very complicated in nature in view of quantification. Actually it is higher version of physical parameter like rotation, vibration, eccentricity, acceleration, turbidity.

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2. Measurement: It means the quantification of any parameter as stated above. Normally we need measurement for those parameters which are varying in nature with time. There are several types of measurements like: 1. 2. 3. 4. Measurements through sensing. Measurements through calculation. Measurements through observation. Measurements through analysis.

Fundamental Idea on Process:

Process means any phenomenon around and in the environment. Process is of three types: Artificial Process: This process is created by human for the benefit of the society to make the life easy and comfort. Industries, educational system, social structures, Rules and regulations are the example of the artificial process. Industrial Process: They mainly are: Agricultural Process. Chemical Process. Medical Process. Mechanical Process. Power Generation (Electrical) Process. Metal (Steel, Cu, Zn, Al etc.) Producing Process. Civil & Construction Process. Electronic Industrial Process. Business & Marketing Process. Hotel & Nutrition Process.

Natural Process: Any process exist in nature is called natural process. Rain, Seasons, Day-Night, Generation chain, Growth, expelling of body waste, Sleeping etc. are examples of natural process. Human has no power to control over natural process than to adopt and adjust. In general all the parameters of any process are blind but sometimes we can sense the existence of the parameters. When we required understanding the status of the process we need the quantification of its parameters. Hence the importance of measurements Page|8

Principles of Measurement Techniques for Physical Parameters:

Physical Parameters are basically measured through sensing conception. It means that to sense the parameter one device is used which is called sensing element. As we already stated that most of the process parameters are blind so the status of the parameter is sensed by the device and create some changes in the process itself which is in turn converted into another parameter. The latter parameter is so chosen that it can indicate the status. The only function of sensing device is to transfer (means to convert) blind parameter into indicating parameter. Hence it is called Transducer.

1. Pressure measurement:
Pressure is defined as Force exerted on unit area. Any environment which has more than atmospheric pressure is termed as Pressure whereas if it has less than atmospheric pressure is termed as Vacuum. This conception of pressure measurement is called as Relative Pressure. There is another conception of pressure measurement exists which is called Absolute Pressure. It is defined as the actual force exerted on unit area. The unit of pressure is Kg/cm, means that 1 Kg force is acting on 1 cm area. When we indicate some pressure with respect to atmospheric pressure then it is called Gauge Pressure. So if a pressure gauge is indicating 0 means the environment has an absolute pressure of 1Kg/cm. Absolute Pressure=( Gauge Pressure+ Atmospheric pressure)Kg/cm

Relationship between Absolute and Gauge Pressures Page|9

Pressure sensors:
The object of pressure sensing is to produce a dial indication, control operation or a standard (4 - 20 mA) electronic signal that represents the pressure in a process. To accomplish this, most pressure sensors translate pressure into physical motion that is in proportion to the applied pressure. The most common pressure sensors or primary pressure elements are shown. They include diaphragms, pressure bellows, bourdon tubes and pressure capsules. With these pressure sensors, physical motion is proportional to the applied pressure within the operating range. We notice that the term differential pressure is often used. This term refers to the difference in pressure between two quantities, systems or devices.

Bourdon Tubes Bourdon tubes are circular-shaped tubes with oval cross sections (refer to Figure).The pressure of the medium acts on the inside of the tube. The outward pressure on the oval cross section forces it to become rounded. Because of the curvature of the tube ring, the bourdon tube then bends as indicated in the direction of the arrow.

Bourdon Tube

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Bellows Bellows type elements are constructed of tubular membranes that are convoluted around the circumference (see Figure 3). The membrane is attached at one end to the source and at the other end to an indicating device or instrument. The bellows element can provide a long range of motion (stroke) in the direction of the arrow when input pressure is applied.

Bellows

Diaphragms A diaphragm is a circular-shaped convoluted membrane that is attached to the pressure fixture around the circumference (refer to Figure 4). The pressure medium is on one side and the indication medium is on the other. The deflection that is created by pressure in the vessel would be in the direction of the arrow.

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Differential Pressure Transmitters Most pressure transmitters are built around the pressure capsule concept. They are usually capable of measuring differential pressure (that is, the difference between a high pressure input and a low pressure input) and therefore, are usually called DP transmitters or DP cells. Figure illustrates a typical DP transmitter. A differential pressure capsule is mounted inside housing. Provision is made in the housing for high- pressure fluid to be applied on one side of the capsule and low-pressure fluid on the other. Any difference in pressure will cause the capsule to deflect and create motion in the force bar. The top end of the force bar is then connected to a position detector, which via an electronic system will produce a 4-20 ma signal that is proportional to the force bar movement.

Differential Pressure Transmitters

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The DP transmitter would be used in an installation as shown in Figure.

2. Flow Measurement:
Flow is a physical parameter which is defined as Quantity passing through per unit time. In another sense it can be defined as the velocity of the fluid multiplied by the area through which it is passing. The quantity may be either Volume-metric or Massmetric. Accordingly its unit can be symbolized as M/hr or Kg/hr. In turns of flow measurement we use some element which senses the establishment of flow. It is called flow element. Flow Detectors: To measure the rate of flow by the differential pressure method, some form of restriction is placed in the pipeline to create a pressure drop. Since flow in the pipe must pass through a reduced area, the pressure before the restriction is higher than after or downstream. Such a reduction in pressure will cause an increase in the fluid velocity because the same amount of flow must take place before the restriction as after it. Velocity will vary directly with the flow and as the flow increases a greater pressure differential will occur across the restriction. So by measuring the differential pressure across a restriction, one can measure the rate of flow.

Orifice Plate The orifice plate is the most common form of restriction that is used in flow measurement. An orifice plate is basically a thin metal plate with a hole bored in the center. It has a tab on one side where the specification of the plate is stamped. The upstream side of the orifice plate usually has a sharp, edge. Figure shows a representative orifice plate. Page|13

Orifice Plate

Tapping used in Orifice Plate

The measured differential pressure developed by an orifice plate also depends on the location of the pressure sensing points or pressure taps. Different taps used are: 1. Flange taps:

Orifice Plate with Flange Taps and Three Valve Manifold

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2. Corner taps:

Orifice Plate with Corner Taps

3. Vena Contracta Taps:

Orifice Plate with Vena Contracta Taps

Advantages and Disadvantages of Orifice Plates

Advantages of orifice plates include: High differential pressure generated Exhaustive data available Low purchase price and installation cost Easy replacement Page|15

Disadvantages include: High permanent pressure loss implies higher pumping cost. Cannot be used on dirty fluids, slurries or wet steam as erosion will alter the differential pressure generated by the orifice plate. Venturi Tubes For applications where high permanent pressure loss is not tolerable, a venturi tube can be used. Because of its gradually curved inlet and outlet cones, almost no permanent pressure drop occurs.

Venturi Tubes

However a Venturi tube does have disadvantages: Calculated calibration figures are less accurate than for orifice plates. For greater accuracy, each individual Venturi tube has to be flow calibrated by passing known flows through the Venturi and recording the resulting differential pressures. The differential pressure generated by a venturi tube is lower than for an orifice plate and, therefore, a high sensitivity flow transmitter is needed. It is more bulky and more expensive.

Annubar An annubar is very similar to a pitot tube. The difference is that there is more than one hole into the pressure measuring chambers. The pressure in the high-pressure chamber represents an average of the velocity across the pipe. Annubars are more accurate than pitots as they are not as position sensitive or as sensitive to the velocity profile of the fluid. Page|16

Annubar Square Root Extractor Up to now, our flow measurement loop can be represented by the high and low-pressure taps of the primary device (orifice type shown) are fed by sensing lines to a differential pressure (D/P) cell. In actuality the differential pressure increases in proportion to the square of the flow rate. We can write this as: P Q2 In other words the flow rate (Q) is proportional; to the square root of the differential pressure. Volumetric Flow Rate = Q P To convert the signal from the flow transmitter, to one that is directly proportional to the flow-rate, one has to obtain or extract the square root of the signal from the flow transmitter.

A Typical Square Root Extractor Installation

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Square root extractors are usually current operated devices so they can be connected directly in the 4-20 mA current loop of a flow transmitter. The output of the square root extractor is again a 4-20 mA signal. This signal is directly proportional to the flow-rate in the pipe-work.

3. Temperature Measurement:
Temperature is a physical parameter which is defined as Thermal status of a body. Thermocouples (T/C) and resistive temperature devices (RTD) are generally connected to control logic or instrumentation for continuous monitoring of temperature. Thermostats are used for direct positive control of the temperature of a system within preset limits. Resistance Temperature Detector (RTD) The full form of RTD is Resistance Temperature Detector. The function of RTD transducer is to sense temperature and produce some changes of resistance of the sensing element itself. For medium temperature applications we use RTDs (normally 50-800 C)

RTD using a Wheatstone Bridge

Thermocouple (T/C) Thermocouple is actually metal couple. It means two different metallic wires are electrically twisted together at one end and the other ends for both the wires are kept normally open. Now if the twisted end gets heated we get some mV generation across the open ends. This mV can be measured by any electrical measuring device. For high temperature applications we use thermocouples (normally 600-1800 C). Page|18

A Thermocouple Circuit

4. Level Measurement:
Level is a physical parameter, which is defined as Occupancy of the space by some fluid. In another sense it can be defined as the depth or height of a fluid with respect to some reference.

Level measurement techniques:

Open Tank Measurement Phigh = Patm + SH Plow = Patm Differential pressure P = Phigh - Plow = SH The level transmitter can be calibrated to output 4 mA when the tank is at 0% level and 20 mA when the tank is at 100% level.

Open Tank Level Measurement Installation

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Closed Tank Measurement We have: Phigh = Pgas + SH Plow = Pgas P = Phigh - Plow = SH The effect of the gas pressure is cancelled and only the pressure due to the hydrostatic head of the liquid is sensed.

Typical Closed Tank Level Measurement System

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Dry Leg System When the low-pressure impulse line is connected directly to the gas phase above the liquid level, it is called a dry leg.

Dry Leg Installation with Three-Valve Manifold If the gas phase is condensable, say steam, condensate will form in the low-pressure impulse line resulting in a column of liquid, which exerts extra pressure on the lowpressure side of the transmitter. A technique to solve this problem is to add a knockout pot below the transmitter in the low-pressure side as shown in Figure. Periodic draining of the condensate in the knockout pot will ensure that the impulse line is free of liquid. In practice, a dry leg is seldom used because frequent maintenance is required. One example of a dry leg application is the measurement of liquid poison level in the poison injection tank, where the gas phase is non condensable helium. In most closed tank applications, a wet leg level measurement system is used.

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Wet Leg System In a wet leg system, the low-pressure impulse line is completely filled with liquid (usually the same liquid as the process) and hence the name wet leg.

A Wet Leg Installation

At the top of the low pressure impulse line is a small catch tank. The gas phase or vapour will condense in the wet leg and the catch tank. The catch tank, with the inclined interconnecting line, maintains a constant hydrostatic pressure on the low-pressure side of the level transmitter. This pressure, being a constant, can easily be compensated for by calibration. Page|22

Measuring Standard and Calibration:

Standards:
To monitor and control the standards some Authorized Organizations are exits in every country. The Organization is called Bureau of Standards like ISI in India. At present the most popular standards of measurements are: British Standards. Metric Standards. ISO Standards.

Calibration:
Calibration is the procedure of meeting the required standard when a measuring device converts a parameter into another parameter. It is also one type of comparison with some standard

General understanding on Control Philosophy and Terminology:

The term Control is valid for every step and activity of our life. Anything without control is meaningless. There are different types of control existing in our life: Technological control: called Process Control Financial Control Administrative and managerial control Sociological Control Political Control

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Control conception
One cyclist is moving on road. Suddenly one barrier appears in front on him. In such a situation either he has to control his speed to avoid the accident or he will be cautioned after the occurrence of the accident. Hence we got two types of controls: a) Feed forward control: where control action is taken before the incident occurs. b) Feedback control: where control action is taken after the incident occurs.

Control Loops:
1. Single Loop Control
By the term single loop control we mean that the control parameters and its control action are dependent on each other but fully independent from the control action of other control loop in either way. It consists of one controller only. The level control of a water tank where one supply line and one delivery line are connected is an example of single loop control. The control action may be placed on any of the lines, operated as per the variation of the levels.

2. Cascade Loop Control:

By the term cascade loop control we mean that more than one control point or control actions are inter-linked i.e. all are dependent on each other directly or indirectly. In cascade conception there may be one particular control called MASTER whereas the others are followers called SLAVE. Cascade loop controls must have several(at least two) controllers in several fashion, generally in the way of ladder or branching. Two tanks are connected in such a way that the delivery of one tank is the supply of the second tank. The first tank has a supply line and the second tank has a final delivery line. In such case, if we want to control the level in both the tanks, then we have to use cascade conception of control.

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Modes of Control
There are erroneous nature of process exist. Depending upon the process characteristics the automatic control feature can be classified by the following mode: a) ON OFF mode: In this mode the final control element actuates either full open or full closed depending upon the signal provided by the decision element. The control in turn may be called logical control. This mode may be used in large Capacitive process. b) Proportional (P) Mode: In this mode the controller provides a signal towards the final control element in such a way that the change of output signal is directly proportional to the error signal between the set value and the measured value. Where dP0 e dP0=K.e. = Change of controller output signal. = Error signal = set value measured value. K = Proportionality constant

This relation indicates that the change of controllers output signal increases if the error is more. The proportionality constant K is called the Gain of the controller. Inverse of K is known as proportional band (P.B) of the controller. Selection of higher proportional band requires making the controller action slower. Here it is clear that the controllers response fully depends upon the selection of the P.B of the controller. The change of controllers response is essential to provide smooth control by synchronizing with process delay. Here output signal remains same for a constant error signal. This mode of control may be used for medium Capacitive and medium delay process. c) Proportional and Integral (PI) Mode: In this mode the controller provides signal towards the final control element in such a way that the change of controller output signal is partially proportional to the time integration error signal to the proportional part. dP0=K1.e. + K2e.dt

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Where

dP0 = Change of controller output signal e K1 K2 = Error signal = set value measured value = proportionality constant = Integral constant : gain : reset.

This relation indicates that the change of controllers output signal increases continuously till the deviation (e) becomes zero. Inverse of K2 is called rate constant.It is clear that the controllers response jointly depends upon the selection of P>B. and the rate constant accurate selection of these constants is essential to provide smooth control for Synchronization of the process. Here output signal increases gradually for a constant error signal. This mode may be used for low capacitive and first process as well as for slave control. d) Proportional, Integral & Derivative (PID) Control: In this mode the controller provides signal towards the final control element in such a way that the change of controllers output signal is partially proportional to the time derivative of the error signal in addition with the proportional and integral parts. dP0= K1.e + K2.e.dt + K3.de/dt Where dP0 = change of controller output signals. e K1 K2 K3 = Error signal = set value measured value = proportionality constant = Integral constant = Derivative constant : gain : reset. : reverse.

This relation indicates that the change of controllers output signal increases/decreases according to the gradient of error signal. This component makes the control action very faster momentarily in the reverse direction and provides retardation on the process. This type of control mode is used for a) Very fast and dynamic process b) Low capacitive and noisy process. c) Feed forward control of any nature

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Importance Industry:

of

Instrumentation

in

The ultimate object of any industry is to produce something to meet the market demands and sustains through competition. Obviously the production cost must be maintained in such a manner that the item capable to extract some value than the production cost beating the prices of other competitors. Hence to create optimum process all related parameters must be optimized either through monitoring of the process parameters or by providing Automation. These parameters can be divided in the following classes to maintain optimum process:

1. Ignoring Parameters are those which could not contribute any

significant disturbance towards optimum process. These parameters can be ignored and not required to measure.

2. Monitoring Parameters are time-based or condition-based parameters

of the process. The indication of these parameters is mostly localized. Few vital indications under this class are also made available at control room.

3. Alarming Parameters are condition-based parameter which always

exists in the process but appears only when the process feels to draw some extra alertness of the operator who will take some corrective time-based activities to continue the healthy process. Normally these parameters are Audio-Visual appearance. Unless the operator performs the necessary corrective action the alarming parameter does not disappear. Double alarms also exist for some vital parameters.

4. Logical Parameters are also condition-based parameters which appears

when some logical activities are conducted for the process. These activities may be either automatic sequential or manual. But duty of monitoring goes to the operator.

5. Controlling Parameters are the proprietors of any process. These

parameters are very fast continually varying and dynamic in nature. A process can be said as optimum if all the controlling parameters are performed as per design norm. Any deviation from the norm, either higher or lower, means incurring loss. This norm is called the desired value or set value.

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Air and oil control logic of A/F Zone 1

Here we will discuss about the air and oil control logic of A/F Zone 1. We can set the SP (set point) in the main PID according to our need. If Process Value (PV) > Set Value (SV) then we need to increase temperature. If Process Value (PV) < Set Value (SV) then we need to decrease temperature.

Process value is less than set value: The main PID sends an output to the air PID. It becomes the set point for the air PID. The PV of the air PID comes from the air flow line through NPT correction unit. Air PID controls the air flow control valve. The signal is divided after the NPT correction box. One goes as PV to air PID and another goes to the division block, which determines amount of oil needed to maintain the air oil ratio. Output of the division block becomes the SP of oil PID. PV of oil PID comes from oil flow line through oil flow transmitter. After comparing the PV with the SP, oil PID generates a signal to control oil flow.

Process value is greater than set value: The main PID sends an output to the oil PID, which becomes the set point of oil PID. PV of oil PID comes from the oil flow line through transmitter. Oil PID generates control signal to control oil flow valve in oil flow line. After this the transmitter signal is divided into two parts. One goes to oil PID as PV and another to multiplication block which determines amount of air required to maintain air oil ratio. Output of multiplication block goes air PID as SP. The PV of air PID comes from NPT correction unit. After comparing PV with SP air PID generates a control signal for air control valve.

Benefit of this control: In case of decreasing temperature first oil flow is controlled then air flow is controlled. So no wastage of fuel oil occurs.

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Conclusion
Electrosteel Castings, a leading name in the field of production of Ductile Iron Pipe always maintains the moto of QUALITY NOT BY CHANCE BUT BY CHOICE. Electrosteel has three plants for production DI Pipe and Fittings. At the Khardah plant Electrosteel has its own power plant, a blast furnace plant and a sinter plant. Blast furnace is referred to as the mother unit of a steel plant. Iron ore as available in nature is basically an oxide. It is changed into a blast furnace either as lump ore or in the form of sinter and reduced to molten iron by the coke at temperature ranging from 1200-1400degree centigrade. Iron ore is melted in the blast furnace plant. Sinter plant is used to mix and treat iron ore fines, coke fines and other waste materials for making solid lumps called sinter. This sinter is used in Blast Furnace to improve furnace productivity. The power plant ensures a continuous supply of power. Thus during this summer training I have acquired a thorough knowledge of the working of ductile iron pipe production plant which will help me in near future during my professional life. I have also understood the principles of various instrumentation techniques and protocols.

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