BOILERAUTOMATION

By
Aizaz Hussain

(2005-NUST-BEE-60)

Imran Tahir

(2006-NUST-BEE-115)

A Project report submitted in partial fulfillment

of the requirement for the degree of
Bachelors in Electrical Engineering

NUST School of Electrical Engineering & Computer Science

National University of Sciences & Technology
Islamabad, Pakistan
2010

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CERTIFICATE
Certified that the contents and form of project report entitled Boiler Automation submitted by
Aizaz Hussain and Imran Tahir have been found satisfactory for the requirement of the degree.

Advisor:

Co-Advisor:

Mr. Habeel Ahmad

Mr. Muhammad Muzzamil

(HOD EE department)

(BIS)

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DEDICATION:

We would like to dedicate this project to:

ALMIGHTY ALLAH
our parents
our teachers
our friends

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ACKNOWLEDGEMENT
We are really thankful to Almighty Allah who has blessed us with courage, effort and
knowledge to complete this project .Our respected advisor Mr. Habeel Ahmad and co-advisor
Mr. Muhammad Muzzamil have given us their due attention in the case of problems which we
encountered during our project. Their guidelines and support was beneficiary to us. Both of them
have encouraged us a lot to do the things in a new and precise way.
We are especially thankful to our friends Bilal Hussain and Faheem Manzoor who have
supported us during queries and questions. Besides them our class mates were also generous
towards us in the case of any help. We would like to acknowledge the efforts made by our lab
administration during this project. They have issued lab apparatus on time and making lab
environment friendly.
Besides all of them we are grateful to BIS (Buraq Integrated Solutions) for their
support and help while doing this project.
At last but not least we would like to appreciate our parents for their project financial
support and encouragement, which helped us to complete project on time.

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ABSTRACT:
Our designed system monitors boilers temperature and pressure and volume
via different sensors which provide input to PLC. The output of PLC controls the
boiler temperature and pressure and gives out the user required volume of steam.
All pressure and temperature variations are shown on HMI screen and are
controlled through HMI. Optionally for safety measures, different automated check
valves are used to release pressure and to inform the concerned authority through
alarm in case of an emergency.

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Contents

1.0INTRODUCTION............................................................................................................................11
BOILER...........................................................................................................................................11
2.0LITERATUREREVIEW....................................................................................................................12
2.1WatertubeBoiler:....................................................................................................................12
2.2FiretubeBoiler:.......................................................................................................................13
2.3Superheatedsteamboiler:.......................................................................................................14
2.4HydronicBoiler:........................................................................................................................14
2.5Fuels:........................................................................................................................................15
2.6Maintenance:...........................................................................................................................15
2.7SafetyConsideration:...............................................................................................................16
3.0HARDWAREPART.........................................................................................................................17
3.1Components.............................................................................................................................17
3.1.1Waterleveltransmitter:........................................................................................................17
3.1.2Pressuresensor:....................................................................................................................18
3.1.3Temperaturesensor:.............................................................................................................19
3.1.4Solenoidvalves:.....................................................................................................................20
3.1.5Safetyvalve:.........................................................................................................................20
3.1.6WaterPump:.........................................................................................................................21
3.1.7Heaters:.................................................................................................................................21
3.1.8Relays:...................................................................................................................................22
3.1.9ReedSwitch:..........................................................................................................................23
3.2.0ProgrammableLogicController(PLC):....................................................................................23
3.2.1PanelBoard:..........................................................................................................................24
4.0SOFTWAREPART..........................................................................................................................25
4.1 PC & PLC Hardware Setup and Configuration.....................................................................26
4.1.1MODBUSserialcommunication:.........................................................................................26
4.1.2 OPC Server:.....................................................................................................................27
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4.2Programming..........................................................................................................................28
4.2.1The File Menu....................................................................................................................28
4.2.2 The Edit Menu..................................................................................................................28
4.2.3 The Simulation Menu.......................................................................................................31
5.0IntroductiontoOpenControlandSCADAsystem.........................................................................32
OpenControl:................................................................................................................................32
Benefits......................................................................................................................................33
SCADASYSTEM..............................................................................................................................34
5.1StyleToolbar............................................................................................................................35
5.2ShapesToolbar.........................................................................................................................36
5.3TodrawanImage.....................................................................................................................36
5.4HowtoApplyDynamics............................................................................................................37
5.5HideDynamic...........................................................................................................................37
5.6DigitalColorDynamic...............................................................................................................39
5.7Howtoapplytag......................................................................................................................41
6.0TLSOFTWARE...............................................................................................................................43
6.1 Code :......................................................................................................................................44
6.1.1Inputs:..............................................................................................................................44
6.1.2Outputs:...........................................................................................................................45
6.1.3CodeExplanation:..............................................................................................................47
6.2Simulation................................................................................................................................64
6.3SCADAimplementation............................................................................................................68
6.4HMIscreen...............................................................................................................................69
7.0REFRENCES...................................................................................................................................71

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LIST OF FIGURES

2.1 water tube boiler..12

2.2 fire-tube boiler......13
2.3

Superheated steam boiler...14

3.1.1.1 pcb of water level transmitter....17

3.1.1.2 water level transmitter hardware...18
3.1.2 pressure guage....18
3.1.3.1 3wire pt100..19
3.1.3.2 temperature sensor..19
3.1.4 solenoid valve.20
3.1.5 safety valve.20
3.1.6 water pump21
3.1.7 electric heaters.22
3.1.8 relay22
3.1.9 reed switch..23
3.2.1 panel board.24
4.1.1 MODBUS Communication ...26
4.1.2 OPC Server..27
4.2.2.1 I/O Labels29
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4.2.2.2 Cust Func Table.30

4.2.3 programmable logic simulator..........31
5.0.1 introduction to SCADA system....34
5.0.2 open graph..35
5.1 style toolbar...........35
5.2 shapes toolbar ......36
5.3 to draw an image......37
5.5 hide dynamics........38
5.6 digital colors...40
5.7 tag browser....41
6.1.1 input relays......44
6.1.2 outputs....45
6.4 HMI Screen...69

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LISTOFTABLES
Table 6.1.1 Relay addresses44
Table 6.1.2 output addresses...46
Table 6.1.3 coustum function...55
Table 6.3.1 Register of addresses PLC....68

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1.0 INTRODUCTION

BOILER

A boiler is a closed vessel which is used to heat up water or other fluids and those heated
or vaporized fluids are then further used for different processes. Boilers are made up of different
materials and composition of these materials change with the passage of time due to demand in
increase in strength of these pressurized vessels. Historically highest grade of wrought iron was
used to make boilers later on steel was used which is stronger and cheaper, with welded
construction, which is quicker and requires less labor. Fireboxes of these boilers are made of
copper it was chosen because of its higher thermal conductivity and its better formability but it
has been replaced by other material such as steel because of the rise in the copper price.
Steam boilers are used to produce saturated or superheated steam which are then used in
different processes like the superheated steam is used to run the turbines which in turn produces
electricity, historically steam boilers were used in trains to run the steam engines, steam is also
used in chiller of central cooling system which helps in maintaining the chemical soft inside the
chiller or otherwise it will get harder and the chiller will not work, it is also used in re-boiling
operations and cooking and there are a lot more functions of steam boiler.

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2.0 LITERATURE REVIEW

There are many different types of boiler, they are as follow
Fire-tube Boiler
Water-tube Boiler
Haycock or Pot Boiler
Superheated steam Boiler
Hydronic Boiler
But most important of these are the water-tube , fire-tube and superheated Boiler.

2.1WatertubeBoiler:
In water-tube boilers the rack of tubes are positioned vertically in the firebox and through
these tubes water flows which gets heated upon flowing through these tubes, these vertical
pipes are called risers and these extends from the water drum which is at the bottom of the
boiler to the steam headers which are at the top of the boilers. These typically surround the
firebox in many layers like a dense forest. As steam bubbles form, they rise to the steam
drum, where the steam exits through the steam header. Following is the layout of a simple
water-tube boiler

Fig2.1WatertubeBoiler

Water-tubes in furnace can be arranged in many different configurations and they are
often used to connect water drums at the bottom and water and steam drum at the top, there exist
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a mono-tube boiler pump is used to circulate water through a succession of coils, this type of
boiler has very fast production of steam but has very less storage capacity. Water tube boilers are
preferred for the high pressure application because of the high pressure steam/water is contained
in smaller diameter pipes which withstands the high pressure.

2.2FiretubeBoiler:
Fire tube boiler consists of boiler shell which is filled with water and perforated with
tubes, there are different configuration of these tubes but horizontal configuration is the common
one .water is partially filled in the water tank and volume is left inside the tank to accommodate
the steam. Long horizontal tubes are called flues and these carry the hot combustion gases
through the water tank and heating the water. The furnace is situated at one end of a fire tube
which elongates the path of the hot gases, thus expanding the heating surface which can be
further increased by making the gases reverse direction through a second parallel tube or a
bundle of multiple tubes (two-pass or return flue boiler)

Fig2.2FiretubeBoiler

The water and steam in fire-tube boilers are contained within a large-diameter drum or
shell, and such unit are often referred to as shell type boiler. Heat from the products of
combustion is transferred to the boiler water by tubes and it goes out from the smokestack. Fire
tube boilers are approximated to 360 psig of steam pressure. In case of fire tube boiler the whole
tank is under pressure so if tank bursts it creates a major explosion and if one need to increase
the steam pressure of fire tube boiler then it is necessary to increase the thickness of shell and
material of tube sheet.

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2.3Superheatedsteamboiler:
Reheating a steam which has been produced in the boiler becomes superheated steam,
this super heated steam is different from the initial steam which is called as saturated steam
because it has less water vapor and condense less rapidly as compare to saturated steam. It also
helps in saving coal water consumption. Basically, superheating increases the heat content and
volume of the steam, making it more fluid and using less for a given work output.

Fig2.3Superheatedsteamboiler

In case of superheated steam boiler there is a box divided in two different spaces called as
superheater header one space is for the saturated steam while other is for the superheated steam,
the saturated steam produced is passed through the pipes situated in the super heater section
where it is superheated and its temperature rises around 370 degree Celsius. This steam might be
collected in cylinder or directly given to the process dependent on it. The temperature of steam
increases in the super heater section but its pressure remains same. Superheated steam is mostly
used to move turbine as superheating steam removes all the droplets entrained in steam which
prevents damage to the turbine blades and all the pipes associated with it.

2.4HydronicBoiler:
There are the boilers that are generally used to generate heat in residential and industrial
purposes. They work by heating the water to preset temperature and then circulating that fluid or
steam throughout the home by radiators or through floors. The fluid is enclosed in the system
and is circulated through motorized pump. This boiler may produce steam on demand and that

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can be used to generate heat or hot water can be circulated to dissipate heat on its way . Hydronic
boiler is the power plant for the central heating system.

2.5Fuels:
There are different sources of heat for the boiler. Source of heat can be natural gas, wood
coal or oil. Nuclear fission is also used as a source of heat for steam generating. These all fuels
are used in burner that on burning burns these fuels and produce heat but in case of our project
we are not using burner, our source of heat is water tube heater that works on providing 220 volts
and these heaters are inserted inside the boiler to heat up water till the time desired pressure and
volume of steam is not achieved.

2.6Maintenance:
To keep the boiler safe, efficient and to avoid the incidents boiler should be maintained
properly there are some steps that will help maintaining the boiler.
Step 1:
Cleaning boiler will allow its inspection for the possible damage and corrosion. Cleaning
and draining will also keep the parts working correctly and reduce the chance of damage to the
mechanism.
Step 2:
Water level is one of the most important that needs a lot of care. If there is a low water
level in the boiler there will be accumulation of material on the boiler surface from inside that
decreases its efficiency, so proper water level must be maintained.
Step 3:
Test all the moving parts like valve , they should function properly because they play a
vital role in keeping the boiler safe,so all the parts should be cleaned and oiled especially the
valves they should easily turned on and shut.

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Step 4:
Keep log of the boiler like when it was last test what incident took at what time this will
help to communicate valuable information to the boiler professional and helps in maintaining the
safety.

2.7SafetyConsideration:
Historically there were incidents regarding the boiler which causes a lot of serious
injuries and the property destruction due to poorly understood principles of engineering. Thin
and brittle metal shells can rupture, while poorly welded or riveted seams could open up, leading
to a violent eruption of the pressurized steam. Collapsed or dislodged boiler tubes could also
spray scalding-hot steam and smoke out of the air intake and firing chute, injuring the firemen
who loaded coal into the fire chamber. Extremely large boilers providing hundreds of
horsepower to operate factories could demolish entire buildings.
A boiler can be extremely dangerous if there is loss of feed water and if permitted to boil
dry if then water is sent to the boiler the water as it contact with the high temperature shell it will
suddenly converts into high pressure steam and continuously supplying water will increase its
pressure to the point that will lead to huge explosion and that pressure generated can not be
controlled even with the safety valve. Draining can also occur if there is a leak in steam supply
lines and the water supply rate is less then the steam production and supply
As there is a lot of destruction that can be caused by the explosion of boilers both to the
human kind and industrial resources, property so we have to minimize the danger of explosion to
the lowest point and in this project we will use different tools to minimize these to the minimum
level so for that we are going to automate the boiler by introducing different components that
will alert the concerned authorities to take necessary actions so that destruction can be controlled
and loss is minimized.

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3.0 HARDWARE PART

3.1Components
Components that we are using in our project are as following
i.

Water level transmitter

ii.

Pressure sensor

iii.

Temperature sensor

iv.

Solenoid valves

v.

Water pump

vi.

Heaters

vii.

Relays

viii.

Reed switch

ix.

PLC

3.1.1Waterleveltransmitter:
There are different types of water level transmitters available in market but they are very
costly so we have made ourselves a water level transmitter for our boiler. We have placed
different carbon cells on a wooden stick with 2, 2 inches gap . As an output these cells attached
to our designed PCB. So when the sensors will sense the water level after 2 inches they will send
the signal to PCB and we can see water level on circuit board through 7 segment LCDs. Also we
will get signal from this PCB to PLC . So we can get signals at 8 different levels with 2 ,2 inch
gap .

Fig 3.1.1 pcb of water level transmitter

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Fig 3.1.1.2 water level transmitter hardware

3.1.2Pressuresensor:
We are using in our project a pressure gauge which will be placed at the top of the boiler
and will continuously show us analog output signal . Its pressure range is from 0 to 10 bar. We
will enter pressure into HMI screen after seeing the presure from this guage .

Fig 3.1.2 pressure guage

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3.1.3Temperaturesensor:
As we have to measure high temperature for steam so we use 3wire pt100 temperature
sensor. It has very high temperature range about -200 to 850c. It will continuously give analog
signal to PLC.
A 3wire Pt100 is a Resistance Thermometer Detector (RTD) . It has three wires that are
connected to Platinum. At a temperature of 0c the resistance of this platinum element is
100.The resistance element of this device is a piece of pure Platinum that is used for
controlling manufacturing process. Hence this is insulated and enclosed in a protective sheath.
3 wires which are connected to the resistance element are also enclosed in this protective sheath
but for easy connection to the field wiring they are extended beyond the end of the sheath.

Fig 3.1.3.1 3wire pt100

Fig 3.1.3.2 temperature sensor

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3.1.4Solenoidvalves:
There are a lot of different kinds of solenoid valves for different purposes,
depending upon the process these can be selected mean if used in pharmaceuticals they
are different in food industry there are different kind of solenoid valves used similarly
they are also used in oil industry which are also different. The common factors that make
them different are there temperature, pressure, material used in making seal and seat of
the valve, material used in making body of the valve, the orifice size and the size of the
input and output ,also there different types of i/o combination valves they are available in
2/2,2/3 ,5/3 configuration .
In this project we are using 2/2 way valves (220 volts Ac) all operated with
relays(24volts Dc) and they can withstand temperature of about 150 degree centigrades
and a pressure of about 8 bars.

Fig 3.1.4 solenoid valve

3.1.5Safetyvalve:
We have placed one safety valve at the top of the boiler so that when
the pressure reaches to its maximum value (75 psi) it will automatically
open to release pressure. Boilers can cause accidental explosion without
safety valve.

Fig 3.1.5 safety valve

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3.1.6WaterPump:
Water pump is used to feed water to the boiler shell it is one of the most important
component, it starts automatically whenever there is water at the threshold level and this will
keep the boilers water level always above the threshold level. As this keeps the boiler away
from boiling dry so it plays a part in the safety issue of boiler. It is also operated with 24 volts dc
relay and needs 220 volts to start pumping water inside the boiler. It can push up to a maximum
of 5 bar pressure.

Fig 3.1.6 water pump

3.1.7Heaters:
Power of these heaters can be varied by supplying different voltages to each heater. They
are used to provide heat so that steam can be generated from water. Each can provide maximum
of about 6000 watts of power if operated with 440 volts it can also be operated with 220 volts but
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in this case there will be low power consumption of about 2500 watts but there will be variation
in rate of steam generation it will be faster if operated with the earlier voltage as compared with
the later one. There are four heaters in boiler shell, two on each side of the boil

Fig 3.1.7 electric heaters

3.1.8Relays:
There are about 10 relays that are used in this project for switching of different
components .we are operating all the components that we are using in our project with these
relays. There are two types of relays that we are using and they differ only in current rating, they
all are operated with 24 volts that is supplied from PLC device.
As heater are heavy duty and they need more current so four of the relays have about 24 amperes
current and all others have about 5-8 amperes.

Fig 3.1.8 relay

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3.1.9ReedSwitch:
Reed switch are similar to the relays but reed switch are operated with permanent magnet
instead of a wire coil. When the magnet is away from the reed switch the switch is open so no
flow of current but when permanent magnet is brought near to it then due to its force the reed
switch closes and current have the path to flow. In this project reed switch is used in the hand
hole so as to see whether the hand hole is open or close because if hand hole is open and heaters
are on then the steam will exit from this hand hole and wont be available for useful process. The
boiler will not start generating heat until and unless this hand hole is closed and it can be seen on
HMI screen with the signal coming from this reed switch. Reed switch is attached on one plane
of the hand hole while permanent magnet is fixed on the other face as shown in the figure:

Fig 3.1.9 reed switch

3.2.0ProgrammableLogicController(PLC):
A digital computer which is used for automation of electrical and mechanical processes is
called PLC. It is used for many automation processes like amusement rides, lighting fixtures or
controlling of factory machinery. It is cost effective, reliable and its programming is easy as
compared to other controllers.
T100MD-2424 is a PLC that is available in our lab. It has 24 digital input,24 digital
outputs and 8 analog I/Os. The analog I/Os are configurable, they can only be 8 analog inputs, no
analog output or they can be treated like 6 analog inputs and 2 analog outputs. 12-24 Volts DC is
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required for its central processing unit and I/Os. If one wants to operate it with 12 volts DC then
a jumper block should be placed at two pin header marked J1-12 near to the power supply
terminal and jumper must be removed if it is operated with the voltage greater then 18 volts DC.
All the information regarding this PLC device can be seen in its manual and inst-md2424 which
explains how this PLC can be installed.

3.2.1PanelBoard:
This is a box where main power is supplied from outside to all the components, it
contains all the relays for different components, microcontroller circuit for water level indicator,
PLC device is also placed in this box.

Fig 3.2.1 panel board

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4.0 SOFTW
S
WARE
E PART
T

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4.1 PC & PLC Hardware Setup and Configuration

4.1.1MODBUSserialcommunication:

MODBUS is an application layer messaging protocol, positioned at level 7 of the OSI

(Open System Interconnection) model,
It provides client/server communication between devices connected on different types of
buses or networks.
It is a method used for transmitting information over serial lines between electronic
devices. The device requesting the information is called the Modbus Master and the
devices supplying information are Modbus Slaves
The SCADA is the MODBUS master and the PLC works as the slave.
MODBUS is a request/reply protocol and offers services specified by function codes.
Every type of devices (PLC, HMI, Control Panel, Driver, Motion control, I/O Device)
can use MODBUS protocol to initiate a remote operation.
Gateways allow a communication between several types of buses or network using the
MODBUS protocol.

Fig4.1.1MODBUSCommunication
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4.1.2 OPC Server:

OPC servers do all the communications between a PC and the PLC. OPC clients tag
named objects receives event driven updates from the server.

Fig 4.1.2 OPC Server

OPC compliant applications such as a HMI (Human Machine Interface, spreadsheet,
trending application, etc can connect to the OPC Server and use it to read and write
device data.
An OPC Server is based on a Server/Client architecture which provides communication
between HMI screen and PLC.
First of all we need to setup the port on which the communication takes place.
These port may be com1 to com4.
Then we need to setup the device name (In our case is boiler).
Then we need to setup folder name (inputs, outputs, data memory and relays folder).
In this folders we may define inputs, outputs etc. According to these inputs and outputs
we may give their addresses and status like r/w(read/write)or ro(read only).
After setting all this user may give the tags to buttons, indicators on HMI screen which
control the output and input status.
OPC sever we have used :
We are using Open control MODBUS serial OPC server

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Single PLC to One PC Running TLServer

This is the simplest configuration when one PLC is connected to the PC, in this case RS232 port
of PLC will be connected to any of the RS232 serial port (COM1: to COM4:) of a PC and run
the TL Server on it, more then one PLC can also be connected to the Server but in this case
RS484 port will be used and that is complex configuration.

4.2Programming

4.2.1The File Menu

New <Ctrl+N>
To create a new ladder logic program
Save <Ctrl+S>
This command saves the whole ladder logic program,
Open

(Local

Drive)

Save (Local Drive)

For TL5 Application (not Applet) we can open or save a file from/to the local hard disk.
Exit
Execute this command to exit orderly from the TRiLOGI program

4.2.2 The Edit Menu

1.

Undo <Ctrl+Z>
Undo the last changes made to a ladder circuit.

2.

Cut Circuit - <Ctrl+X>

It lets us move a block of circuits from one part of the ladder program to another part or

into another file.

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3.

Copy Circuit (Ctrl+C)

We can copy a block of circuits from the current ladder program and store them into the

clipboard for pasting into another part of this ladder program or into another ladder program file
altogether.
4.

Paste Circuit <Ctrl+V>

When we execute this command, the block of ladder circuit which we "Cut" or "Copy"

into the clipboard will be pasted just before the currently selected circuit.
5.

I/O Table <F2>

Open up the I/O Table for defining label names for the PLC's I/O. I/O Definition Tables

Fig 4.2.2.1 I/O Labels

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Fig 4.2.2.2Cust Func Table

This table is meant for us to define a label name for a custom function
6.

View I/O Type on Ladder <F3>

Toggle between display and no display of the I/O type for ladder logic contacts on the screen
7. Edit Custom Function <F7>
Opens up the Custom Function Editor window for us to enter the TBASIC

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program

4.2.3 The Simulation Menu

Run (All I/O Reset) <Ctrl+F9>

When executed, all I/O bits (including inputs) are cleared to OFF state, all integer data
are set to 0 and all string data are set to empty string. Then the "Programmable Logic Simulator"
window will open for us to conduct the simulation test of your TRiLOGI ladder program.

Fig 4.2.3 programmable logic simulator

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5.0 Introduction to Open Control and SCADA system

OpenControl:

This is a is specialized software designed for Industrial Automation to provide real-time

visualization to the Executives, Management, Operators and Maintenance Staff.

OpenControl is state-of-the-art HMI/SCADA software developed by Buraq Integrated

Solutions for Industrial Automation and real-time Control.
OpenControl Software is based on industrial standards such as OPC (OLE for Process
Control) and TCP/IP for rapid and secure connectivity to multiple PLCs and Industrial
Controllers.
OpenControl provides a central control room monitoring environment, ideally suitable
where multiple brand of hardware is deployed.
OpenControl software provides true client server architecture with choice of multiple
operating systems thus using existing hardware and protecting existing investment.
Using OpenControl Industrial Automation software, you will be able to improve product
quality, reduce downtime, increase performance and provide cost savings. Fault finding
and rapid diagnostics become easy with OpenControl Suite.
OpenControl system is suitable for all industries where the requirement of monitoring
and controlling is critical.

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Benefits

Open control software is very flexible and can be used in any type of industry .

This software is easy to learn and can be rapidly deployed and maintained in house by the
end users .

System integrators prefer products that offer reusability, rapid coustimization and less
programming .

The deployment of OpenControl facilitates to achieve:

9

Increased Production

Improved Quality

Low Production and Operating Costs

Increased Safety and Security

Reduced Downtime

Quick Diagnostics and Maintenance

The additional business benefits of OpenControl are:

9

Better Return on the Investment

Improved Decision Making

Meeting International Standards

Real-time Reporting

Instant Performance Indicators

Equipment Efficiency & Downtime Analysis

Finding true cost of Production

Early Warning Alarm System

Right Information to Right People

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SCADASYSTEM
SCADA system generally refers to an industrial control system .
This is a computer system monitoring and controlling a process.
The process can be industrial or infrastructure like manufacturing, production, power
generation or water treatment
SCADA system reads the measured value (flow or level ) and send the set points to PLC .
SCADA system is use to operate the PLC according to the desired input enter by the user on
HMI screen.
SCADA system operates the PLC and OPC server which is use to communicate between
PLC and the SCADA system is Modbus serial server.

Fig 5.0.1 introduction to SCADA system

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Fig 5.0.2 open graph

The figure above shows the Open Graph screen with its basic components, including the
Color Palette, Main toolbar, Draw toolbar, Arrange toolbar, Font toolbar, and Dynamics
toolbar.
This section describes the features of the Open Graph screen, as shown above. It also
describes the tools used to create displays and make dynamic connections to data values.

5.1StyleToolbar
The Style Toolbar provides convenient access to commonly used style functionality.

Fig 5.1 style toolbar

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5.2ShapesToolbar
The Shapes toolbar, shown below, is used to draw the common shapes like Line,
Multiline, Arc, Polygon, Rectangle, Hexagon, Circle, Chord and Pie.

Fig 5.2 shapes toolbar

5.3TodrawanImage

In the Shapes Toolbox, click

2- Click on the Drawing Area, where you want to draw an Image.
3- A dialog box will open, browse for the image.
4- Select the image and then click open. The image is loaded into the Drawing
Area.
5- Now you can draw as many Images as you can. To stop drawing Image selector tool
from the

Shapes toolbar.

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Fig 5.3 to draw an image

5.4HowtoApplyDynamics

This chapter explains how to apply dynamics on display objects by using tags coming
from various OPC data servers. The objects are animated and controlled by the values of those
tags or data points. We can apply multiple dynamic connections to a single object. We can create
dynamic connections with functions contained in the Dynamics menu. Types of dynamic
connections include size, location, slider, rotation, dial, flash, hide, disable, analog and digital
color, fill, pick, analog and digital selector and animator.

5.5HideDynamic
The Hide dynamic on the Dynamics toolbar causes objects to become hidden when the
value of the digital data point to which it is connected goes either true (logical 1) or false (logical
0) as you configure it.
To define Hide for an object:
1-Select an object from the Shapes Toolbar e.g. Circle.
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2-

Select the Dynamics tab from the Properties window which is located in the
Bottom, shown below:

3-Selects the Hide Dynamic as shown below:

Fig 5.5 hide dynamics

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4- Hide is the dynamic selected.

5- Object Name is a name specified to this object.
6- Property Inspector is a property sheet containing a collection of property pages. The
Property Inspector dialog box lets you view and make changes to the object parameters.
7- Hide dynamic can also be selected from the Dynamics Toolbar.

5.6DigitalColorDynamic

The Digital Color dynamic on the Dynamics toolbar allows the color of the object to
change based on a digital event. The color connections are prioritized in the order in which they
are created. Therefore, if two data points are true at the same time, the higher-priority color
connection takes precedence. If none of the connected data points is true, the object is displayed
in its original color.
The Color connection is used to indicate states such as alarm conditions and
temperature changes, or to notify operators of the flow in a pipe.
To create a digital color connection:
1- Select an object from the Shapes Toolbar e.g. Circle.
2-Select the Dynamics tab from the Properties window which is located in the bottom, shown
below:

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3- Selects the Digital Color as shown below:

Fig 5.6 digital colours

4- Digital Color is the dynamic selected.
5- Object Name is a name specified to this object.
6- Property Inspector is a property sheet containing a collection of property pages. The
Property Inspector dialog box lets you view and make changes to the object parameters.

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7- Digital Color dynamic can also be selected from the Dynamics Toolbar, as shown
below:

5.7Howtoapplytag
The Tag Browser, shown in the figure below, is a tool that helps us in configuring our
OpenGraph application. Using the Tag Browser, we can connect to the OPC servers and
databases, find the available tags needed to configure the type of display that you wish to build,
and send them to OPC clients. We can also browse for aliases and variables to help you create
your displays. The Tag Browser also displays global data tags (Expressions, Value Sets, Recipes
and Groups).

Fig 5.7 tag browser

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The Tag Browser allows us to browse conveniently for several basic types of data from a
single location accessible from most Open Graph applications, including:

1- OPC tags
2- Aliases
3- Variables
4- Network nodes
5- Databases
A tag (sometimes called a "point") is a specification that, once sent to a client, will direct
our customized software to perform a desired function.
Using an intuitive point-and-click interface, the Tag Browser enables us to add tags rom the
following:

1- OPC Server(s)
2- Configuration Alarm(s)
3-Global Script(s)
More detail of these software can be found from the help manuals of the respective
software.

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6.0 TL SOFTWARE
OVERVIEW:
In software the user enters the volume of the steam that is required while the
temperature is controlled whose range is from 0---150 degrees centigrade and also the pressure is
entered by the user through HMI screen which the user read from the pressure guage which in
turns send signal to the PLC all the variations are controlled by the PLC and on achieving the
desired results alerts the user through different ways like there are LED used on the HMI screen
which light up when ever the desired result is achieved and if the user opens any available valve
it will also be shown on the HMI screen via those LEDs also all the field devices are controlled
by the PLC. In the beginning the user have to set the value of the volume for the steam that he
needs but there are certain limitation because of the level sensor that we are using the maximum
the user can enter is 175 liters while the minimum is 70 liters because in boiler the heating rods
should always be dipped in the liquid so in our case the heaters rod are completely immersed in
the water when there is 70 liters. There are also stop button used whose purpose is whenever user
wants to stop the operation he can do so also there is an option if user wants to empty the water
shell for inspection purpose or for some other purpose he can do so. Further explanation will be
presented in the code menu. One thing to remember in coding that HMI can only change relays
and data memory, so inputs shown on HMI screen are basically sending values to relays and data
memory. So coding involves using of relays, instead of digital inputs. In case of analog inputs,
value is stored in data memory of PLC.

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6.1 Code :

6.1.1Inputs:

These are the inputs that user have the access to set them from HMI screen. Inputs used are
all relays, because we can control inputs of PLC only through external sources. We cant control
PLCs inputs through industrial automation suite (Open Control SCADA system). But relays can
be controlled by SCADA system. The input relays we defined are as follows:

Fig 6.1.1 input relays

These are the relays that we have used in our project addresses for these relays which is to be
entered in the OPC server software are as follow
Table 6.1.1 Relay addresses
Serial no

Relay

address

START

1025

STOP_1

1026

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VALV_A

1027

VALV_B

1028

SP_O_VALVE

1029

Stsrt is used to give user the option to start the operation mean start the boiler whereas if user
wants to halt the system he can do so by pressing the relay named as STOP_1, VALV_A and
VALV_B is used to give the operator the choice to open either Valve A or Valve B. if operator
wants to empty the water shell he can do it by pressing from HMI screen and for that
SP_O_VALVE is used.
6.1.2Outputs:

Outputs can be addressed either by there names or by their bits. In our case we have
addressed the output by there names because this is the easy way, addressing by the bits is
difficult as user have to remember output bit number of respective output field device ,using
names of the field devices as the output addressing is the most easy and memorable way.one
thing must be remembered that output 7 and 8 are for PWM. Field devices that we have used
which are to be controlled via the PLC, there output addressing is as follow;

Fig 6.1.2 outputs

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SO_VALVE is used for the spill out vlave through which fluid can be spilled out from
the tank while PR_VALVE, VALVE_A, VALVE_B are the output valves through which the
steam is exited and two valves named A and B are used if the operator wants to use that steam in
some process he can open valve A while for the other process he can open valve B.
VALVE_MTR is the valve that is placed right after the water pump this us used to stop the back
flow of water from the tank while WATER_PUMP is used to insert water inside the main
tank.HEATER_1, HEATER_2, HETER_3, HEATER_4 are the four heaters that we have used to
heat the water inside tank to make steam out of it while the SCDA _ALARM is used to alert
operator that the desired results have been achieved where as ALARM_1 is used to alert the
same operator if for any reason the volume, temperature or pressure is increasing after achieving
the required results then it will start, but if the pressure,volume or temperature have increased to
the critical level that it can cause a very large scale damage to the people as well as to the
building then this ALARM_2 will be ON and will remain ON until and unless the parameters
decreases from the critical values. They are addressed in the OPC server software by the
following addresses;
Table 6.1.2 output addresses
Serial No

Output

Addresses

SO_VALVE

257

PR_VALVE

258

VALVE_A

259

VALVE_B

260

VALVE_MTR

261

WATER_PUMP

262

HEATER_1

265

HEATER_2

266

HEATER_3

267

10

HEATER_4

268

11

SCDA_ALARM

269

12

ALARM_1

270

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13

ALARM_2

271

6.1.3CodeExplanation:

Clock energizes custom function every one second. When this custom function is energized,
following code will run

As per our requirement the minimum steam volume is 7o liters so user have to enter
equal to or greater then this otherwise the code wont proceed so when the user enter required
steam volume it is saved in the memory location 1and the steam volume must also not exceed
175 liters otherwise there will be error. Basically data memory is used to get input data from
SCADA system. We store the value of data memory from HMI which changes the input
functions according to defined in PLCs custom function.when the user inputs steam volume
equal to or greater then 70 liter or less then 175 liter then it will set other input function which
cause the execution of another custom function which s as follow:

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As the above custom function executes it will clear all the valves ,water pump.it will also
clear STOP_1 which will be explained later it also clearOPEN_VALV so user will have no
option to open Valve A and B in the beginning .further more when the user enter START button
from rellay then the above custom will execute

SYS_ON and START was made closed by the user previously here it will check either
the hand hole is open or closed because if the hand hole is open then there is no use of operating
the boiler because then there will be no storage of steam and it will go out from the hand hole
which is also the wastage of resources and that steam which is going out from the hand hole can
not be used for any sort of process because some process need the pressurised steam like in case
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of turbines it needs a lot of pressure to move the turbines to make electricity and also continuous
flow of steam is also required in central heating system with certain pressure thats why it is
necessary that the hand hole remain close down if there is need of steam. This circuit will cause
the execution of another custom function namely SYS_CHKED , explanation of this custom
function is as follow:

So another circuit will short down making its way to another custom function . Above
custom function will short SYS_CHKED1. The circuit is as follow:

We have used the clock of time period 1 second so as to check after every second that
either the value of sys_chked1 is changed or not and it will make execution of another custom
function named CHK_WATER which is explained as follow;

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So the previous start button pushed by the user after setting the value of required steam is
cleared of here so that the respective custom function of the START do not execute. Here the
water level is determined and if it is less then the level detectors 35 liters while in real it will be
very much less then 70 liters then it will call custom function which is at number 29 and named
in the custom function list as FILL_WATER is as follow:

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It will short another circuit ans make clear others. The circuit of STRT_MTR is as
follow;

And the corresponding custom function is as follow;

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While filling the water we are opening the PR_VALVE, VALVE_A, VALVE_B so that
all the air present initially inside goes out and the pressure remain constant if it was not done
then the pressure guage should show some pressure which is not due to water but due to the air
present inside the tank and the pressure guage will show presssure when water is inserted in the
tank, it is also necessary to open the VALVE_MTR because if it is not open the water will not
flow inside the tank and also there will be damage caused to water pump and this valve.
In the above custom function number 12 named CHK_WATER if the first condition
comes out to be wrong then the second will be seen and if it comes out to be true then the
following custom function number 30 named STRT will execute.

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Water level have reached to its highest level so the water pump will be switched off and
all the valves will be make close another circuit will turn on

START_OPRT custom function will execute on shortning of the above circuit. Uptill
now water has reached to its maximum height and the operation will begin so in the following
custom function heaters are turned on and the process of steam genertation will begin and the
water level will starts to fall down and this felling down level of water is used to estimate the
volume of the steam generated by making the another circuit short starting from PVT which
contains the normally closed inputs which is opposite to the water level detector which contains
the normally open inputs. As the water level increases it will make the inputs named IN_1
.IN_8 close and the corrseponding function will execute which will give out different valuesof
water level on every shortning of water level indicators graphite with the low voltage signal
coming from low potential of PLC and this value of increasing and decreasing water level is
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stored in the memory location DM[2] while the steam volume circuits conatian normally closed
IN_1IN_2 so It will work oppositely to the water level indicator. Figure A shows the above
circuit corresponding custom function while Figure B shows the water level circuit.Figure C
shows the steam volume circuit;

Figure A

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Above is Figure B.

Above is the custom function of the corresponding IN_1 which is stroing a value of 35 in
memory location 2. Similarly other contains the following values;
Table 6.1.3 coustum function
Custom function name

Value contain

C_70

DM[2]=70

C_105

DM[2]=105

C_140

DM[2]=140

C_175

DM[2]=175

C_210

DM[2]=210

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C_245

DM[2]=245

C_280

DM[2]=280

Figure C

Going back to the custom function number 15 named START_OPRT it aslo contain the
third condition which on becoming true will cause another circuit to short. It says that IF
memory location 2 contains a value of 280 then CALL 31 which is also a custom function and it
will make this circuit to work

The custom function of the respective above circuit contains

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The heaters were on when the water level reached 245 liter level but then it reaches 280
liters they will be made turn off and the spill out valve will open so that the extra water above
245 level is spilled out and this level is achieved.

As the water level goes down the volume will increse and the clock of 1 second time
period is used to update volume value and as the user set volume is achieved it will short another
circuit

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Custom fnction of the respective above circuit contains

Here we need to uncheck the START_1 so that it do not check the water level again
because if the user puts the maximum steam volume then it will start again filling the tank when
the volume reaches to its max but due to clearing it here that circuit switches off. The heaters are
shut down and thr pressure releif valve is open and choice has been given to the user either he
wants to open Valve A or B.

The custom function named USER _PRESS is use to take pressure vlaues from the user
which he take from the pressure guage and enter it through HMI screen and the clock is again
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used to update the values that user enter .the custom function defiend above is explained as
follow;

When the user enters the values into HMI screen it is saved in the memory location DM
[4] but there are certain limitation for the pressure that should build inside and for the safety
measures steps are taken to minimize the damage in case of emergency. Max pressure of 60 psi
is a safe pressure that can build inside but as it reaches ti 60 psi it will inform the operator by
scada alarm and again the pressure relief valve will be open and user will have a choice either to
open valve A or B, but if it does not occure for any reason and the pressure remains on
increasing then if it goes beyond 65 psi but remain less then 75 psi then it will make another
circuit short which is as follow;

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It will make the execution of another custom function named HEATER_OFF1 whose
function is defined as follow;

The scada alram was made on previously and it will remain ON untill and unless the
pressure is decreased below 60 psi but in case it goes on increasing the above custom function
will execute in which another alarm ALARM_1 hich is a physical alarm will start, all the heaters
are made clear they are shut down over here . Again the pressure relief valve is open and the user
have been given an option to open any of the two valve.similarly same is the circuit for the
temperature that increases when the heaters are ON and sesnsor is used which will be sending the
values of the increasing temperature. Its circuit is as follow;

The custom function for the above circuit is as follow;

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The values are saved in the data memory DM[3] and this inputs to the PLC device at
analog to digital convertor port number 2. We also have limitations for the temperature like if its
goees beyond 423 kelvin and remain less then 430 kelvin then it will make anochtr circuit short
which is explained earlier which is adjacent with the PRESSUE_1 and its function is also
explained abovebut if it remain goes on increasing and goes beyond 430 kelvin it will make
another circuit short by making TEMP_2 close else if the temp remain below 423 kelvin none of
the TEMP_1 and TEMP_2 will be will be made close. The custom function for TEMP_2 is as
follow;

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The two alarms SCDA_ALARM and ALARM_1 were made ON previously but as
temperature increase above 430 kelvin another physical alarm named ALARM_2 will be mae
ON whose purpose is to inform all the people inside the building and to evacuate tht building and
all the heaters area again made OFF if previolsy they failed to switch off.similar is th case fot the
pressure if its goes beyond 75 psi the manual safety valve whose value is fit at about 75 psi will
open and the pressure built inside tank will be released through this safety valve and the pressure
will decrease to its mnimun and as it goes below 75 psi the ALARM_2 will be switched off and
as it goes below 65 psi another ALARM_2 will be switched off and same if its goes beyond 60
psi all the alarms will be switched off. The circuit for the pressure_2 is as follow;

Custom function for HEATER_OFF2 is explained above.

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We have used relays for opening of the vave A and valve B whose circuit are as follow;

OPEN_VALV is made closed in the custom function whenever there is need to evacuate steam
from the boiler while VALV_A and VALV_B are the relays used which make the respective
valve open by choosing from the HMI screen.

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6.2Simulation

This is how our simulation look like initially VOl_3 and PR_VALVE is checked because
it is programmed like this that whenever DM[1] = DM[11] check VOL_3 which will inturn open
the PR_VLAVE and check OPEN_VALV this time user have the choice to open either of the
valve by checking any of the vlave relay.

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Now the user have entered the volume of steam required so it will make check SYS_ON
indicating that the volume entered was correct volume otherwise it will remain uncheck if it is
out of range so the user have to check the START button tfor furhter execution of the code and
here it will check the water level initially the water level was at zero so the water pump will start
puming water inside the tank and when it reaches to it reaches to its final value the water pump
and the pump valve will close down whereas the heater will switch on and it aslo checks the PVT
because the heater are switched on so by heating the water will start converting into steam so the
water level will be falling down and the steam volume will increase whose values will be stored
in DM[11] which is the custom function of the corresponding PVT inputs which will switch on
the circuit as it goes close. START_1 is also checked here at this point which execute the custom
function which switch on the heaters.

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It is shown over here that user have enterd the steam of volume which is saved in the
memory location DM[1] and DM[2] shows the volume of water remaining in the tank after
achieving the deired volume of steam which is stored in memory location DM[11].
The simulation diagram below shows what will happen when the desired volume is
achieved .when the required volume is achieved the heaters will shut down VOL_3 is checked
OPEN_VALV is also checked which inturn will provide the option for the user to open any of
the available valve for evacuation of the steam.IN_1 is still on which shows the current water
level which it is showing as 35 liters but in real there will be 70 liter of water thisis because as
the graphite cell in the water level indicator makes the second level indicator of the system will
assume that the water level have reached to 35 liters which is the minimum water level but in
real minimum water level is 70 liter at which the heater rods are completely immersed in the
water keeping them away from heating dry.

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The last simulation diagram shows that when initially the water pump starts filling
water and the STOP_1 button was pressed then the water pump will close down also the pump
valve will close down and if the user wants to spill out the water he can do so by pressing down
SP_O_VALVE from HMI screen. The operator can open the spill out valve any time when the
system is off meaning that the pressure inside the boiler is zero and the heaters are switched off.

6.3SCADAimplementation

Inputs

Table6.3.1RegisteraddressesofPLC:
1-96

Outputs

257-352

Timers

513-576

Counters

769-832

Relay

1025-1536

Data memory

4-1001---4-5000

Timer PV value

4-0129---4-0192

Counter PV value

4-0257---4-0320

Time[1]

4-0513

Hour

Time[1]

4-0514

Minute

Time[1]

4-0515

second

Date[1]

4-0516

year

Date[1]

4-0517

Month

Date[1]

4-0518

Day

Date[1]

4-0520

Day of week(string)

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6.4HMIscreen
Basically HMI screen is use to monitor the whole system. We just apply the input signal
on screen according to that input desired functionality is performed. The reason of designing the
HMI screen is to make the automatically controlled device for ease of users and their desire. We
have made our HMI screen through which input and outputs of boiler unit are controlled. We
have different input buttons according to which the different outputs are controlled.
Our HMI screen looks like this as shown below;

Fig 6.4 HMI Screen

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The user can enter the required steam volume on the left hand side under the heading of
user datas volume, he can also put the pressure values read from the pressure guage. While the
three meter in the center below will show the Pressure built inside tank ,temperature and the
steam volume inside tank respectively. The two switches tagged start and stop is use to start and
stop the operation of the boiler ahile the switch shown with each valve can be operated so as to
open respective valves of respective switches.
On the right hand shown STATUS consist of leds of respective devices, which will
switch on when there respective device switches on, like if Heaters are on the corresponding
LED to the Heater will remain on as long as heaters are switched on. The 0.0L shown on the tank
shows the volume of water inside the tank whose value will increase or decrease depending on
the volume of water inside the tank.
The delievery pipes will change itsw colour when ever steam or water pass
through it, like pipes conneccted with water pump and the pump valve will change its solour to
sky blue whenever water flows through it which depends upon the switching of water pump,
similar is the case for the pipes attatched for the purpose of drain. The pipes for evacuation of the
steam will change its colour to red when ever there is passing of steam while to show which
valve is open and close, the pipe that are attatched on the right side of the Valve A and B will
change its colour depending upon which one is opened.

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7.0 REFRENCES

http://www.mckenziecorp.com/boiler_tip_8.htm
http://www.cip.ukcentre.com/pt100.htm
http://en.wikipedia.org/wiki/Boiler
http://www.tpub.com/content/construction/14279/css/14279_14.htm

http://www.scif.com/safety/safetymeeting/Article.asp?ArticleID=5

www.absoluteastronomy.com/topics/Fire-tube_boiler

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