Four-Week Training Report

on Instrumentation
This comprehensive report details the four-week industrial training undertaken by Sahil (Roll No: 220011000051) at
Milkfood Limited from 10/08/2023 to 08/09/2023. The training, a crucial component of the Diploma in Electronics &
Communication Engineering programme at Government Polytechnic, Ambala City, provided invaluable hands-on
experience in industrial instrumentation and processes.

Under the guidance of Dr. Adish Bindal, Head of the ECE Department, this report aims to showcase the practical
knowledge gained, the tools and technologies encountered, and the real-world applications of theoretical concepts
learned in the classroom. The following sections will delve into the intricacies of various instruments, control systems,
and industrial practices observed during the training period at one of India's leading dairy product manufacturers.

RS
by Ravinder Singh
Introduction to the Training Programme
The four-week training programme at Milkfood Limited was meticulously designed to bridge the gap between academic theory and industrial application in the field of
instrumentation. Commencing immediately after the 2nd-semester examinations, this intensive training period from 10/08/2023 to 08/09/2023 provided a unique
opportunity for hands-on learning in a real-world industrial setting.

The primary objective of this training was to immerse students in the day-to-day activities of a large-scale manufacturing facility, focusing on the intricate web of
instrumentation that forms the backbone of modern industrial processes. By engaging directly with state-of-the-art equipment and experienced professionals, trainees
gained invaluable insights into the practical aspects of industrial automation, process control, and quality assurance.

1 Week 1: Orientation and Safety Training

Introduction to Milkfood Limited, safety protocols, and basic instrumentation principles.

2 Week 2: Process Control Systems

Hands-on experience with PID controllers, temperature indicators, and pressure transmitters.

3 Week 3: Sensor Technologies

In-depth study of various sensors including RTDs, thermocouples, and transducers.

4 Week 4: Quality Control and Automation

Exploration of automated quality control processes and final project presentation.
Introduction to Milkfood Limited
Established on March 31, 1973, Milkfood Limited has emerged as a powerhouse in India's dairy industry. With a rich
history spanning five decades, the company has consistently delivered high-quality dairy products to consumers across
the nation. Milkfood Limited specializes in the production of milk powder, ghee, casein, and demineralized whey powder,
catering to both domestic and international markets.

The company's commitment to quality and safety is evident in its numerous certifications, including ISO 22000:2005 for
food safety management systems, ISO 14001:2004 for environmental management, and FSSAI certification ensuring
compliance with India's food safety standards. These certifications underscore Milkfood's dedication to maintaining the
highest standards of product quality and operational excellence.

Patiala Plant Jalandhar Plant Moradabad Plant

The flagship facility, specializing in Focused on casein production, Specializes in demineralized whey
milk powder and ghee production. utilizing advanced acid casein powder, employing cutting-edge
Equipped with state-of-the-art spray manufacturing processes. membrane filtration technology.
drying technology.
Essential Tools for Industrial Instrumentatio
During the training period at Milkfood Limited, trainees were introduced to a variety of essential tools crucial for
maintenance, repair, and installation of industrial instrumentation equipment. These tools form the foundation of any
instrumentation technician's toolkit, enabling precise and efficient work in the field.

The soldering iron, a fundamental tool in electronics, was extensively used for creating reliable electrical connections.
Trainees learned the importance of selecting the right soldering iron temperature for different components and practiced
proper soldering techniques. Complementing the soldering iron, solder wire and flux were utilized to ensure strong,
conductive joints in electrical circuits.

Precision Screwdrivers Pliers and Wire Electric Tester Precision Tweezers

Essential for adjusting and
Cutters Vital for quick voltage For handling small
maintaining sensitive Used for manipulating wires checks and ensuring components and intricate
instrumentation and components in tight electrical safety. circuitry.
components. spaces.
Digital Multimeter: The Swiss Army Knife of Electr
The digital multimeter emerged as an indispensable tool during our training at Milkfood Limited, serving as a versatile instrument for
measuring various electrical parameters. This device's ability to measure AC/DC voltage, resistance, DC current, and perform continuity
tests made it an essential companion for troubleshooting and maintenance tasks across the facility.

At the heart of the digital multimeter is its LCD display, providing clear, numerical readings that eliminate the guesswork associated with
analog meters. The probe lead sockets, typically color-coded for easy identification, allow for quick connection to the circuit under test. The
range selection dial, a prominent feature of most multimeters, enables users to select the appropriate measurement range and function,
ensuring accurate readings across a wide spectrum of electrical values.

1 Voltage Measurement 2 Resistance Testing

Capable of measuring both AC and DC voltages, essential for Allows for quick verification of component values and
power supply checks and circuit analysis. detection of faulty resistors or breaks in circuits.

3 Current Measurement 4 Continuity Testing

Primarily used for DC current measurements, crucial for Features an audible beep for quick checks of wire integrity
analyzing power consumption and detecting current leaks. and circuit connections.
Resistance Temperature Detector (RTD):
Precision in Temperature Measurement
Resistance Temperature Detectors (RTDs) played a crucial role in the temperature measurement systems at Milkfood Limited. These highly
accurate sensors leverage the principle of electrical resistance change in certain materials, typically platinum, to measure temperature
with exceptional precision. During our training, we extensively studied two common types of RTDs: thermocouples and PT100 sensors.

Thermocouples, consisting of two different metal wires joined at one end, generate a small voltage proportional to the temperature
difference between the junction and the reference point. On the other hand, PT100 sensors, made of platinum with a resistance of 100
ohms at 0°C, offer even higher accuracy and stability, especially in the temperature ranges critical for dairy processing.

Feature Thermocouple PT100

Temperature Range -270°C to 1800°C -200°C to 850°C

Accuracy ±0.5°C to ±2°C ±0.1°C to ±0.3°C

Response Time Fast Moderate

Cost Lower Higher

Temperature Indicator: The Visual Interface of
Thermal Control
Temperature indicators emerged as crucial components in Milkfood Limited's production processes, serving as the primary visual interface
for temperature monitoring and control. These devices play a pivotal role in ensuring product quality, safety, and consistency across
various stages of dairy processing, from pasteurization to storage and transportation.

During our training, we observed the implementation of both analog and digital temperature indicators. Digital indicators, with their
precise numerical displays, were predominantly used in critical process control areas, offering easy-to-read temperature values and often
incorporating alarm functions for out-of-range conditions. Analog indicators, with their familiar dial faces, were still found in use,
particularly in areas where a quick visual check was sufficient or in backup systems.

Data Acquisition Signal Processing Display Communication

Receives input from Converts and scales the Shows the processed Transmits data to control
temperature sensors like RTDs sensor signal to a readable temperature on a digital or systems or data loggers for
or thermocouples. temperature value. analog interface. further action or recording.
Transducers: The Energy Conversion Specialists
Transducers played a fundamental role in the instrumentation systems at Milkfood Limited, serving as the critical link between physical
phenomena and electrical signals. These devices, designed to convert energy from one form to another, form the backbone of modern
industrial automation and control systems. During our training, we delved deep into the principles and applications of various transducers
used in dairy processing.
At their core, transducers consist of two primary components: the sensing element, which interacts directly with the measured physical
quantity, and the transduction element, which converts this interaction into a usable electrical signal. This conversion allows for the precise
measurement and control of various process parameters, enabling efficient and consistent production processes.

Pressure Transducers Flow Transducers

Convert fluid or gas pressure into electrical signals, crucial for Measure and convert liquid flow rates into electrical signals,
monitoring and controlling pressure in storage tanks and essential for precise control of ingredient mixing and product
pipelines. transfer.

Level Transducers pH Transducers

Provide electrical signals corresponding to liquid levels in tanks Convert the acidity or alkalinity of solutions into electrical
and silos, ensuring optimal inventory management and process signals, critical for quality control in fermentation processes.
control.
PID Controller: The Brain of Process Control
The Proportional-Integral-Derivative (PID) controller emerged as a cornerstone of process control systems at Milkfood Limited. This sophisticated device plays a crucial
role in maintaining stable and optimal conditions across various production processes, from temperature regulation in pasteurization to pressure control in
homogenization. During our training, we gained hands-on experience in configuring and tuning PID controllers for different applications.

At its core, a PID controller continuously calculates the error value as the difference between a desired setpoint and a measured process variable. It then applies a
correction based on proportional, integral, and derivative terms, each contributing uniquely to the control action. The proportional term provides an immediate response
to the current error, the integral term addresses accumulated error over time, and the derivative term responds to the rate of error change, anticipating future behavior.

PID Controller Interface PID Response Curve PID in Action

Modern PID controllers feature user-friendly interfaces Visualization of a typical PID control response, Real-world application of PID control in maintaining
with digital displays and intuitive adjustment illustrating how the controller brings the process precise temperature in a dairy processing vat, crucial
mechanisms for easy configuration and monitoring. variable to the desired setpoint over time. for product quality and safety.
Pressure Transmitter: Guardian of Process Integrity
Pressure transmitters emerged as critical components in the instrumentation ecosystem of Milkfood Limited, playing a vital role in ensuring the safety and
efficiency of various dairy processing operations. These sophisticated devices convert liquid or gas pressure into precise electrical signals, providing real-time data
crucial for process control and monitoring. During our training, we explored the intricacies of different types of pressure transmitters and their applications in the
dairy industry.
The core functionality of a pressure transmitter lies in its ability to sense pressure changes through a diaphragm or other pressure-sensitive element and convert
this mechanical deformation into an electrical signal, typically 4-20 mA or a digital output. This standardized output allows for seamless integration with control
systems, enabling automated responses to pressure fluctuations and ensuring consistent product quality.

Pressure Sensing 1
The transmitter's diaphragm flexes in response to applied pressure,
initiating the measurement process.
2 Signal Generation
The mechanical deformation is converted into an electrical signal
through various methods such as capacitive, piezoresistive, or strain
Signal Processing 3 gauge technologies.
Internal electronics amplify and condition the raw signal, applying
temperature compensation and linearization as needed.
4 Output Transmission
The processed signal is converted to a standard output format (e.g.,
4-20 mA) for communication with control systems.