SMALL YET POWERFUL PACKAGE SOLUTIONSfujielectric.co.in/wp-content/uploads/2016/10/9-flyer-new.pdf · 2. Combustion Control. 3. Air flow control. Reduction of fuel cost by optimizing

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SMALL YET POWERFULPACKAGE SOLUTIONS

Package Solution : PCS

Boiler- Control System

Benefits

Solution

In the process industries, boiling water to make steam is a very important process. Modern boilers are designed to meet the needs of a variety of industries and their associated process-es. Consequently the engineers at Fuji Electric have researched and developed a PLC / DCS based boiler control system to match the performance and operating requirements of boiler.

The following control operations are important for Boiler System:

1. Boiler Feed Water Control (Drum Level Control).

2. Combustion Control.

3. Air flow control.

Reduction of fuel cost by optimizing Combustion Control, using oxygen analyser.

Micrex SX-PLC has pre defined function block of 3 element drum controller to improve the boiler efficiency.

VFDs reduces the boiler FD & ID fan’s electricity power cost.

1. Micrex SPH PLC / VIEW XX.

2. SCADA System.

3. 02/CO Analyzer.

4. VFDs

5. Solution varies depending on level of automation required & size of boiler.

Fuji Electric India Pvt. Ltd.409-410, Meadows, Sahara Plaza, Andheri Kurla Rd, Andheri(E), Mumbai- 400059, Tel:- +91-022-40104870/71E-mail : [email protected] www.fujielectric.co.in

Three Element Drum Level Control Block

Three Element Drum Leven Control Block

The performance of the three-element control system during transient conditions makes it very useful for general industrial and utility boiler applications. It handles loads exhibiting wide and rapid rates of changes. Plants which exhibit load charac-teristics of this are those with mixed, continuous, and batch processing demands.

It is also recommended where normal load characteristics are fairly steady, but upsets can be sudden, unpredictable and / or a significant portion of the load.

FEI/INST/BOILER/023

Key Features

BTU Package : BTU PAQ

Accepts Analog Input: 4-20mA, 3 inputs ( Flow X1, Temperature X2).Accepts flow inputs from clamp-on ultrasonic flowmeter & temperature input from transmittter as per above schematic. Thermal Energy Function: BTU /KWH ( embedded math function). Keypad: Four Key membrane.Display : 7 segment LED, 8 digit totalizer & 4 digit rate.Operating at 230Vac.Transmitter Power Supply: 24VDC/50mA.Programmable parameters: Zero, full scale, Decimal position, unit scale.Non-volatile Memory for storing configuration parameters.Calibration through software.

Options:1. Retransmission : 4-20mA ( Linear Proportional to indication).2. Four Relays (5A/230VAC) for Alarm.3. Communication : RS 232 or RS-485 (2-wire), MODBUS protocol.

Mechanical Data: Panel Mounting.1. Cut out size :92 mm x 92 mm.2. Outer dimension: 96 mm x 96 mm x 120 mm( Depth).

Enclosure : General Purpose Plastic.

Package Ordering Guide:

FEI/INST/BTU/024


Package Solution : REMON PAQ

Effluent Monitoring & Reporting

Key Features

Fuji Offerings

Online monitoring enables you to identify unacceptable conditions that may occur immediately. Continuous Effluent Monitoring ensures that effluent level in discharged water is within regulatory levels & any problems identified immediately.Fuji Electric globally strong in Infrastructure Automation, Water Solution & Incineration Automation Solution. Real time monitoring of these treatment systems helps ensure compliance & minimizing the risk of Effluents discharge. Real Time Monitoring alerts your engineers if concentrations of Effluents cross- regulatory levels.High speed Micrex Series PLC & Monitouch HMI help End -User for smooth operation & monitor.

Pump Control & flow monitoring remotely. PLC / HMI based solution for user-friendly operation & easy maintenance.No signal cables required from remote pumping stations, reduce cost of installation.Cloud based solution, does not require software installation.Web based Monitoring System manage all your effluent treatment plants on a single platform from anywhere.Accurate flow measurement through Ultrasonic Flow meter.Keeps automatic record of above parameters.

Flow Meter for Effluent discharge monitoring & raw water consumption.

Programmable Logic Controller for Monitoring & Control Field devices.

Human Machine Interface for local Interface as well as data transmission for remote monitoring.

Package Solution : REMON PAQ

Irrigation Monitoring & Control

Key Features

Fuji Offerings

To monitor & control the over exploitation of natural water resources by one area or user, so that all other consumers can have the benefits of same, Fuji offers remote monitoring & control system with easy access.

Pump start stop control & monitor the status. Pump Control & Flow Monitor from remote.

Water distribution control & flow consumption monitoring.

Can interlock automatically with consumption / usage to avoid over consumption.

PLC / HMI based solution for user-friendly operation & easy maintenance.

No signal cables required from remote pumping station. Reduce cost of installation & maintenance.

Cloud based solution, does not require software installation.

Web based monitoring system manage all your effluent treatment plants on a single platform from anywhere.

Accurate flow measurement through Ultrasonic Flow Meter.

Keeps automatic record of above parameters.

SCADA for local & remote monitoring station.Programmable Logic Controller for field interface.Flow Meter for effluent discharge monitoring.Water Level Transmitter for monitoring water tank level including submersible type.Human Machine Interface for local interface as well as data transmission for remote monitoring.

FEI/INST/REMON/025


Fuji provides complete furnace automation solution as it requires good knowledge of below components that Fuji supplies on its own that enables long term support and optimized solution.. PLC. Instrumentation. Software. Process. KnowledgeThe set values of zone temperatures is automatically controlled by controllers. The combustion air flow and gas/Oil flow measured by orifice plates complere with flow transmitter. Flow of fuel / air is controlled by a signal received from temperture controller through oilflow valves. Furnaces preassure control maintains positive furnace pressure. Interlocking and sequential control with respect to charging and discharging done through PLC logic in the instrument panel / control. Safety for abnormal conditions provided.Records of various inputs-provide a check on the condition. Small furnace control is by PID Controller & Mid-size furnaces are offered with PLC based control system.

Objectives: The process control requirement is............

1. Required Temperature control for the billet heating through correct Air Fuel ratio for proper combus-tion.2. Uniform temperature across the cross-section and along the length. 3. Correct Oxygen Control to avoid surface De-carbonization of steel containing Carbon or reduce scal-ing.4. Proper furnace response for variation in loading and intermediate stoppages.

Process:

The furnace will have multiple firing zones with burners located on the front wall and also the two side walls the waste gases after preheating the stock will be allowed to escape through flue ports located near the charge end wall and finally through underground flue tunnel to the chimney.For Auto Temperature Control loop Fuji provides Microprocessor based controller to achieve the desired control strategy. The actual programming of the set point and controls were made possible through Industrial HMI. Ratio Controller continuously and automatically control air and fuel inputs to each zone of the burner. To provide optimum corrections in the set ratio over-riding control is provided using IN-SITU 02 sensor data, in Percentage Oxygen.Provision for local manual control is also provided. Similar custom control strategy is used for furnace draft control. Real Time -Trends, Custom Report, Alarms and Animated Mimics are additionally provided through HMI.

Permormance

1) Temperature variation were now less than+/-1%.2) % 02 control was now less than 5%.3) Temperature uniformity for monitoring resolution were now better than+/-degree C.

BenefitsLower access of 02 prevents emission of CO, Uniformity of temperature in process, Quality of Metal sheet by way of lower scaling, Report generation, Historian and Universal Data Server for other industrial network connectivity.

System Description

Furnace Automation : Reheat Furnace, Heat Treat Furnace

Return On Investment

Special Features Savings Fuel & Scale Investment Payback

1.Control of desired temperature regimes and air- fuel ratio are possible.

Fuel saving 5-10% depending upon current state of operation.

Rs.20 Lakh( Varies based on level of automation & furnace size ).

4 to 5 months2.Control of furnace pressure will reduce air ingress and in turn control on oxygen inside furnace.

3.Operation interaction for control of temperature is lesser.

FEI/INST/FURNANCE /026


A New Engineering Concept

Pre-engineered package solution for Continuous Emission Monitoring System

Smart solution that simplifies the way you handle regulatory compliance:-

MyCEMS from Fuji Electric India is a standard package solution designed in consideration to CPCB requirements that helps you meet data requirements and emissions compliance. It monitors SO2, NO in stack.

Leaving aside above, our CEMS solution ranges from pre-engi-neered packaged system to more complex custom-engineered system that measures multiple gases. We also provide end to end service solution through our state of the art gas analyzer service centre.

Includes:-

- ZRE Gas Analyzer for SO2, NO measurements.

- Heated probe with filter.

- Auto Blowback.

- Dual Channel sample cooler with auto-drain.

- Condensate Alarm.

- Controller Card.

- Sample Pump.

- Auto-Calibration Solenoid Valves.

- 19” Rack.

- Heat Traced Tubing, 1/4”PTFE ( 50 meters) with Temperature Controller.

- V9 HMI based Data Accquisition System for CPCB connectivity.

- Calibration Cylinders & Regulators.

Options:-

Unique Features:-

1. “Plug & Play” type Sampling System.

2. Takes Remedial Action in case of failures.

3. Integrates “Autocal” command from Analyser.

4. Blowback for optimization of Cleaning Cycle.

5. Proven references in Paper, Sugar, Power, Cement & other Industries.

is suitable for :- design concept:-

AMBIENT CONDITIONS :-

TEMPERATURE : 40 Deg C

HUMIDITY LEVEL : 95% Non-Condensing

PROCESS DATA:-

TEMPERATURE : Upto 550 Deg C

PRESSURE : 10 mmWC below Atm.

MEASUREMENT RANGES:-

NO: 0-1000ppm / 0-2000ppm

SO2: 0-1000/ 0-2000ppm

19” Integrated module housing the complete SHS & Gas Analyzer.

Intelligent- Remote diagnostics & engineering.

Compact - Smaller Foot Print.

Transportable system.

Reliable - Reduced cost of maintenance.

Future expansions upto five gas measurements.

Cloud based CPCB Server.

FEI/INST/REMON/025


PHX Paperless RecorderInnovative Data Management System

Compact PCS unit combining recording, controlling and networking

Cost effective data acquisition data and management product with enhanced network support.

Large wide display 7”/10” Std. report generation to predict energy cost and poduction data with IT enabling to send email /sms. 8GB storage options forgreater flexibility in USB.

GOAL

Analog Inputs: Upto 48.

Auto Output: Upto 24(Analog,

Relay, SSR).

Local IO/Remote IO.

PID Auto Tune: Available.

Modbus protocol.

Email / Sms/Webserver.

Isolation of 1500Vrms(option).

0 to 50 C.

Rugged Construction for high

reliability .

SOLUTION

IN BRIEF

Flexible, Scalable & Robust.

Reduced system cost.

No Software knowledgementrequired.

Password protected.

BENEFITS

SnapshotPHX is a paperless recorder that displays measured data on the 7”/10” Touch Screen ( keyless TFT WVGA( 800x480) LCD display with LED backlight in real time and stores data in USB.

The type of inputs such as thermocouple, resistance bulb, D.C.Voltage (current), etc can be set upto 48 channels at the maximum. The data stored in memory can be regenerated on the screen, and the use of supplied support software allows the data to be regenerated on a PC Screen. The data recorded in csv format can be directly read in a spreadsheet such as Excel, which facilitates the processing on a PC.

PHX is all network enable supporting Ethernet (Web/FTP Server), RS485 / RS232C, email / Sms function, 8-way communication for integration with 3rd party devices, direct printer, USB memory, barcode reader, mouse and keypad interface. Recorder is equipped with unique Fuzzy PID Control capability as std. It has an option of CC-Link and profibus communication. It also includes ramp / soak function for pattern control.

Front panel is IP65 compliant and rear case IP20 with size of channel is 155 (H) x 215 (W) x 185(D) in mm. Panel cut-out of 134x189. Measuring cycle is 100ms for DC linear signals and 200ms for Thermocouple / RTD signals. Recorder is equipped with various display capabilities including bar graph display, trend, digital display, event summary etc. Other functions include Burn-out, Input Filter, Scaling, Macros, Alarm / Control Relays, Analog Re-transmission output. All channels are 3-way isolated with 14 bit resolution.

Salient Features:-* Standard quick-start monitoring screens with tool for customs screens--- Application & data-viewer

software

* Multi-zone optimal control technology using model predictive control reduces thermal interference from adjacent zones, and thus enables more precise control with Auto tune/Fuzzy logic.

* Analog outputs can be configured for control of retransmission.

* Versatile recording functions in portable USB memory.

* Effective presentation of field content on the web ( option)

* Enhanced functions like programmable 64 ramp / soak, cascade and hi-speed control, motorized-valve control, heater current (CT).

Ordering Code

FEI/INST/PHX/028


Next-generation, Explosion ProofPID Controller (PXFE series)

PXFEExplosion-proof Model

Available in various sizes

PXFStandard Model

48X48mm, 48X96mm, 96X96mm

Higher performance, Safety and multi-functionality are achieved while ensuring well-established quality of Fuji Electric Temperature Controller at most competitive price.Features• Bright and clear color LCD display (white PV display) with the highest

character height in the market• Fast sampling speed of 50 ms and fast control calculation of 100 ms• Universal input to accept every input signals• Extremely-compact design with only 58mm depth behind panel which

enables downsizing of equipment• The market's first "simple power-monitoring function"• Cooperative operation between devices via RS-485 communication• Every type of temperature control is possible including 2-degrees-of-

freedom PID, motorized valve control.

PXFE - Explosion proof enclosure incorporated!• Flameproof control station with glass window & control elements• Classification: Zone 1 & 2, IIB, T5, IP 65• Enclosure Material: Cast Aluminum alloy, LM6 Constr.• Transmitter power supply: SMPS 24Vdc for powering transmitter• Separate push-buttons for easy replacement• 2-DOF PID Algorithm for accurate control• Ramp / Soak control – 64 steps

Beautiful front panel• Bright and clear white PV display with highest character height

• High contrast, wide viewing angle, and easy-to-see colored LCD

• 11-segment display which makes alphabet easy to distinguish

Universal input supported• Accepts any input including thermocouple, Pt100,

voltage, and current. You can switch them simply by parameter change.

Bus-powered USB interface equipped• Directly connectable to PC via USB port with optional

cable. No need for supplying electricity to the main unit.

Simple power-monitoring function• Helps you save energy

Cooperative operation of devices via network•SV can be transmitted among PXFs via a network. Synchronous temperature rise control is available in combination with 2-degrees-of-freedom PID.

Fast control• Fast sampling speed of 50 ms and fast control calculation of 100 ms

Ultracompact design – PXF Std. controller• Only 58mm depth behind panel enables downsizing of equipment

58mm depth


Reactor Control SystemGlobal ReferenceIntroduction & Package Overview

Reactor Automation is a popular package for the manufacturer of chemicals used in dyes like ONA, PNA, ONCB, PNCB. This package is developed for their requirement of Reactor Control system.

Business objectives is to automate the multi-ple Reactor Controls through supervisory control system located at centralized control room.Fuji is the only supplier to offer complete Instrumentation, Control and Power Electronic Solution through its own mfg range.

Reactor Control System

Objective: 1- Valves, actuators, and cooling system control2- Recipes management, data acquisition and

recording3- Control:

NitrogenVaccumTemperature control

4- HMILocal (POD touch panel)Remote PC Remote web pages monitoring

Hardware:� PLC� SCADA Software� PHL paperless recorder� POD� PUMA

PackageSolution

Benefits

• Integrated reporting.

• Efficient alarm system provided allowing the

operator to quickly isolate and identify failure,

reducing the amount of downtime.

• Customized XY- plots for pressure v/s

temperature provided to check on-line

reactor healthiness.

Identified user of similar Application

This system finds its application in all major industries where Auto-clave / Reactors are utilized.

USP of all package solution from Fuji is that most of the hardware, software, engineering and domain knowledge is its own and being sold across the globe. Such platform provides long term support to our customer and protects their investment in our solution.

Other packages we serve: Boiler Automation | Furnace Automation | MyCEMS System | Stability Chamber Automation | BTU Meter | PHX Paperless Recorder | PXF Temperature Controller | Reactor

Control System | E�luet Monitoring & Reporting


Package Solution: PCS

Stability Chamber Automation:

Purpose :

The purpose of stability testing is to provide evidence on how the quality of a drug substance or drug product varies with time under the influence of a variety of environnmental factors such as temperature, humidity, light and to establish a re-test period for the drug substance or product under recommended storage conditions. Hence, Pharmaceutical Stability Chamber serves as an important quality attribute for the product.

Regulatory Requirement:-

Qualification of stability chamber is governed by 21CFR Part-11 as per FDA requirement and automation system should comply to the same.

Features of our system:-

HMI & Modular controller based control system with safety feature like................

High temperature safety cut-off.

Electrical overload cutoff relay for compressor.

Time delay for compressor switch ON.

Other features include:-PC Based SCADA software to monitor and provide supervisory control of many stability chambers in central control room.

GSM based email system for escalation of alarm.

Long term data storage.

.

..

Solution:

1. Monitoring & Control Of Stability Chamber for temperature, RH and events.

2. Recioes management, data acquisition. and recording, login, calibration, validation, offset, parameter , limits & adjustments, system page, audit trail, events status, user & alarmview, graphs etc.

3. Control :

a) Temperature

b) Humidity

c) Operator Events

4) SMS, email, voice alerts ( option).

FEI/INST/Stability Chamber/031


Documents

SMALL YET POWERFUL PACKAGE SOLUTIONSfujielectric.co.in/wp-content/uploads/2016/10/9-flyer-new.pdf · 2. Combustion Control. 3. Air flow control. Reduction of fuel cost by optimizing