PLC Based Boiler Automation

Plc based industrial boiler automation
MEKELLE UNIVERSITY
ETHIOPIAN INSTITUTE OF TECHNOLOGY

TECHNOLOGY- MEKELLE (EIT-M)
(EIT
PLC BASED INDUSTRIAL BOILER AUTOMATION
FINAL GRADUATING THESIS
IN PARTIAL FULFILLMENT FOR T

THE AWARD
Of
“BACHELOR
BACHELOR OF TECHNOLOGY
TECHNOLOGY”
IN
ELECTRICAL AND COMPUTER ENGINEERING
UNDER THE SREAM OF INDUSTRIAL CONTROL AND INSTRUMENTAION

ENGINEERING
Submitted by:
Gebregeworgis Tadesse
Meles Gebremariam
Kidanu Asgedom
Tesfay Gebrelibanos
Tesfalidet Tamiru
MEKELLE ETHIOPIA JUNE 2013
Final year thesis, electrical and computer engineering 1

MEKELLE UNIVERSITY
ETHIOPIAN INSTITUTE OF TECHNOLOGY

TECHNOLOGY-MEKELLE
MEKELLE
CERTIFICATE
This
is is to certify that the project entitled, industrial boiler automation using plc submitted by
Gebregeworgis Tadesse, Meles Gebremariam, Kidanu Asgedom, Tesfay Gebrelibanos and
Tesfalidet Tamiru in partial
artial fulfillment of the requirements for the award of Bachelor of
Technology Degree in electrical and computer engineering at the Ethiopian Institute of
Technology- Mekelle (EIT
(EIT-M),
M), is an authentic work carried out by them under my
supervision.
Date: 21-06-2013
Assistant Professor Sisay Teklay

(Advisor) signature
Approved by:
Industrial control chair: Assistant professo

professor Sisay Teklay
Department Coordinator: Zanachew Muluneh
(MSc. Eletirc.power)
Department of Electrical and Computer Engineering
Engineering. Signature
Ethiopian Institute of Technology
Technology-Mekelle
Final year thesis, electrical and computer engineering i

Table of Contents
List of tables .................................................................................................................................... i
List of figure ................................................................................................................................... ii
Candidate declaration .................................................................................................................... iii
Acronyms ....................................................................................................................................... iv
Acknowledgment .............................................................................................................................v
Abstract .......................................................................................................................................... vi
CHAPTER ONE ..............................................................................................................................1
1. Introduction..................................................................................................................................1
1.1 backgrounds ........................................................................................................................................ 1
1.2 Objective of the thesis ......................................................................................................................... 4
1.5 Methodology ....................................................................................................................................... 6
1.6 overview of the thesis.......................................................................................................................... 7
1.7 Statement of the problem .................................................................................................................. 10
CHAPTER TWO ...........................................................................................................................12
2.Programmable Logic Controller .................................................................................................12
2.1 Introduction ....................................................................................................................................... 12
2.2. History of PLC ................................................................................................................................. 13
2.3 Plc hardware .................................................................................................................................... 14
2.3.1 CPU:- ......................................................................................................................................... 15
2.3.2 Memory:-.................................................................................................................................... 16
2.3.3 Input modules and output modules:- ........................................................................................... 16
2.3.4 Programming Terminal:- ............................................................................................................ 17
2.3.5 Signal modules ........................................................................................................................... 17
2.4 Programming device: .................................................................................................................... 17
2.5 Specifications to use PLC ................................................................................................................. 19
2.6 working of plc:- ................................................................................................................................. 19
CHAPTER THREE .......................................................................................................................27
3.Function of components used for our thesis work ......................................................................27
3.1.1. Switches ........................................................................................................................................ 27
3.1.2. Timer ............................................................................................................................................. 29
Final year thesis, electrical and computer engineering ii

3.1.3 Sensors ........................................................................................................................................... 29

3.2.1 Water pump: ................................................................................................................................... 39
3.2.2 Solenoid valve ................................................................................................................................ 39
3.2.4 Relays ............................................................................................................................................. 41
3.3 Communication of the plc .......................................................................................................42
CHAPTER FOUR .........................................................................................................................47
4. Plc based industrial boiler automation .......................................................................................47
4.1 hardware and software system design .....................................................................................47
4.1.1. Software design process ................................................................................................................ 47
4.3Assignment of input/output and ladder diagram development .................................................59
4.3.1 Level and ph sensor controller ....................................................................................................... 59
4.3.2 Fire detector sensor controller ........................................................................................................ 60
4.3.3 Temperature sensor controller........................................................................................................ 61
4.3.4 Oxygen and furnace oil sensor controller ...................................................................................... 61
4.3.5 Pressure sensor controller .............................................................................................................. 62
4.3.6 Flow sensor controller .................................................................................................................... 63
4.4 Over all boiler automation I/O assignment ..............................................................................64
4.5 Result and discussion ...............................................................................................................65
CHAPTER FIVE ...........................................................................................................................67
5. Conclusion and Recommendation .............................................................................................67
5.1 Conclusion ........................................................................................................................................ 67
5.2 Recommendation............................................................................................................................... 67
Reference ....................................................................................... Error! Bookmark not defined.
Appendix........................................................................................................................................69
A)Field devices ....................................................................................................................................... 69
B)Material required ................................................................................................................................. 70
C)Ladder diagram ......................................................................................................................72
Final year thesis, electrical and computer engineering iii

List of tables
Table 2.7 comparison of plc program types ..................................................................................26
Table 4.3.1 input/output assignment of level and PH sensor ........................................................59
Table 4.3.2 input/output assignment of fire detector sensor ..........................................................60
Table 4.3.3 input/output assignment of temperature sensor ..........................................................61
Table 4.3.4 input/output oxygen and furnace oil sensor ................................................................61
Table 4.3.5 I/O assignment of pressure sensor ..............................................................................62
Table 4.3.6 I/O flow Sensor assignment .......................................................................................63
Table 4.4 over all input/output assignment....................................................................................64
Final year thesis, electrical and computer engineering i

List of figure
Figure 1.1partial views of power plants and industries that require automatic boiler
controller ..........................................................................................................................................3
Figure 1.5over all block diagram of industrial boiler automation ...................................................6
Figure 1.6a overview of the thesis ...................................................................................................7
Figure 1.6b industrial boiler process block diagram .......................................................................9
Figure 2.3 plc hardware components and power flow direction ..................................................15
Figure 2.6 PLC operational cycle flow chart .................................................................................21
Figure 2.7Programming PLC steps flow chart ..............................................................................24
Figure 3.1 normally open switch ...................................................................................................27
Figure 3.1.1 normally closed switch ..............................................................................................28
Figure 3.1.3 Fig water injection of control system ........................................................................32
Figure 3.1.3.2schematic diagram of pump moor and level sensor ................................................32
Figure 3.1.3.3 ph sensor block diagram .........................................................................................33
Figure 3.1.3.4 PH sensor control block diagram ...........................................................................34
Figure 3.1.3.5 block diagram of flow control system ....................................................................36
Figure 3.1.3.6 components of oxygen sensor ................................................................................38
Figure 3.2.2solenoid valve .............................................................................................................39
Figure 3.2.4Relay Components .....................................................................................................41
Figure 3.3a connecting plugs .........................................................................................................43
Figure 3.3 b connecting pins ..........................................................................................................44
Figure 4.1.1.1 level sensor controller flow chart ...........................................................................48
Figure 4.1.1.2 temperature sensor controller flowchart .................................................................49
Figure4.1.1.3 PH sensor controller flowchart ................................................................................50
Figure 4.1.4 Fire sensor in boiler automation flow chart ..............................................................51
Figure 4.1.1.5 pressure sensor controller flow chart .....................................................................52
Figure 4.1.1.6 Flow sensor controller flowchart............................................................................53
Figure 4.1.1.7 Flowchart for oxygen sensor ..................................................................................54
Figure 4.1.1.8 over all flow chart ..................................................................................................55
Figure 4.1.1.9 simplified over all flow chart .................................................................................56
Final year thesis, electrical and computer engineering ii

Candidate declaration
We hereby declare that the work, which is being presented this thesis pepper, entitled
industrial boiler automation using plc in partial fulfillment for the award of degree of
”bachelor of technology” in department of electrical and computer engineering under
stream of industrial control and instrumentation engineering and submitted to the department
of, electrical and computer engineering Ethiopian institute of technology Mekelle, Mekelle
university is a record of our own investigations carried under the guidance of Sisay Teklay
,department of electrical and computer engineering Mekelle University.
We have not submitted the mater presented in this thesis any ware for the award of another
degree.
Gebregeworgis Tadesse
Meles Gebremariam
Kidanu Asgedom
Tesfay Gebrelibanos
Tesfalidet Tamiru
Ethiopian institute of technology Mekelle, Mekelle University
Assistant professor Sisay Teklay
(Thesis advisor)
Final year thesis, electrical and computer engineering iii

Acronyms
AI Analog Input
AO Analog Output
CPU Central processing unit
DI Digital Input
DO Digital Output
DTE Data Terminal Equipment
GAL Generic Array Logic
IEEE Institute of Electrical and Electronic Engineers
LAN Local Area Network
MAP Manufacturing automation protocol

MODICON Modular Digital Controller
PC Personal computer
PID Proportional integral and derivative
PLA Programmable Logic Array
PLC Programmable logic controller
PROM Programmable Read-Only Memory

RAM Read and write memory
ROM Read only memory
RTD Resistance temperature detector
SCADA Supervisor control and data acquisition
TTL Transistor-transistor logic

UART Universal Asynchronous Receiver/Transmitter
Final year thesis, electrical and computer engineering iv

Acknowledgment
First of all, we would like to express our gratitude and sincere thanks to our respected
advisor Assistant professor Sisay Teklay for his professional guidance, advice, motivation,
endurance and encouragements during his supervision period. The present work would have
never been possible without his vital supports and valuable assistance.
Also we want to thank Mekelle University, especially electrical &computer engineering
Department, for teaching us and for creating different learning opportunities from freshman
year up to now. Finally, we would like to express our sincere thanks and appreciation to
industrial control and instrumentation engineering staffs which was much cooperative by
giving advice and encouragement.
Above all, we would like to thank the almighty of GOD!!!
Final year thesis, electrical and computer engineering v

Abstract
A Boiler or steam generator is employed wherever a source of system is required. A boiler
incorporates a firebox or furnace in order to burn the fuel and generate heat; the heat is
initially transferred to water to make steam; this produces saturated steam at ebullition
temperature. The higher the furnace temperature, faster the steam production. The saturated
steam thus produced can then either be used immediately to produce power via a turbine and
alternator, or else may be further superheated to a higher temperature; this notably reduces
suspended water content making a given volume of steam produce more work. In this paper,
we propose the parameters like the temperature of the steam, the level of water, control of
feed water pump, Pressure of the steam has to be measured and critically monitored for
reliable and safe operation of the generation unit. This kind of operation with critical
importance can be carried out efficiently and implemented employing Programmable Logic
Controller (PLC).
Final year thesis, electrical and computer engineering vi

CHAPTER ONE
1. Introduction
1.1 backgrounds
In the past, boilers in an industrial complex were considered a necessary evil. However
today’s a business manager know this is no longer the case? Boilers are required to maintain
maximum steam generation efficiency, maximum reliability, and comply with both stringent
air emission and safety regulations. To achieve this goal we need modern control software.
A boiler is a closed vessel which is used to heat up water or other fluids and those heated or
vaporized fluids are then furthered 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 high thermal conductivity and its better
formability but it has been replaced by the 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 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.
Over the years the demand for high quality, greater efficiency and automated machines has
increased in the industrial sector and power plant generations. Power plants and large
industrial sectors require continuous monitoring and inspection at frequent intervals. There
are possibilities of errors at measuring and various stages involved with human workers and
also the lack of few features of microcontrollers. Thus this thesis takes a sincere attempt to
explain the advantages the companies will face by implementing automation into them. The

boiler control which is the most important part of any industrial sector, power plant and its
automation is the precise effort of this thesis. A Programmable logic controller is a solid
state user programmable control system with Functions to control logic, sequencing, timing,
arithmetic data manipulation and counting Capabilities. It can be viewed as an industrial
computer that has a central processor unit, memory, input output interface and a
programming device. PLCs were first introduced in the 1960’s. The primary reason for
designing such a device was eliminating the large cost involved in replacing the complicated
relay based machine control systems.
In the 1960's Programmable Logic Controllers were first developed to replace relays and
relay control systems. Relays, while very useful in some applications, also have some
problems. The main problem is the fact that they are mechanical. This means that they wear
down and have to be replaced every so often. Also, relays take up quite a bit of space.
These, along with other considerations, led to the development of PLCs. More
improvements to PLCs occurred in the 70's. In 1973 the ability to communicate between
PLCs was added. This also made it possible to have the controlling circuit quite a ways
away from the machine it was controlling. However, at this time the lack of standardization
in PLCs created other problems. This was improved in the 1980's. The size of PLCs was
also reduced then, thus using space even more efficiently.
The 90's increased the collection of ways in which a PLC could be programmed (block
diagrams, instruction list, C, etc.). They also saw PLCs being replaced by PC's in some
cases. However, PLCs are still very much in use in all sorts of industries, and it's likely that
they will remain there for quite some time.
In order to automate an industry, power plant and minimize human intervention, there is a
need to develop a SCADA (Supervisory Control and Data Acquisition) system that monitors
the plant and helps reduce the errors caused by humans. While the SCADA is used to
monitor the system, PLC (Programmable Logic Controller) is also used for the internal
storage of instruction for the implementing function such as logic, sequencing, timing,
counting and arithmetic to control through digital or analog input/ output modules various
types of machines processes. Our thesis is focused only to PLC automated boiler system.
Systems are used to monitor and control a plant or equipment in industries such as oil and

gas refining, water and waste control and transportation. This project which includes
applications of PLC reflects the true and exact nature of operation of a boiler used
in an industry where steam energy is greatly required for other useful operations to take
effect. The current project is controlled and automated fully by logo made PLC which uses
logo software. The overall logic that is the ladder diagram for the boiler operation
is designed with the help of this software which is then downloaded into the PLC CPU
memory. The physical parameters that are taken from water level, temperature and pressure.
This PLC accepts the outputs from those sensors incorporated within the boiler, evaluate
them and generate appropriate signals which will ultimately use to run on or terminate the
heater or the water pump.
Figure 1.1 partial views of power plants and industries that require automatic boiler
controller
PLC applications are extensively used in industry to control and facilitate repetitive process
such as manufacturing cell management, fly-by-wire control, or nuclear plant shutdown
systems. One of these applications is industrial automation which includes numerous
automated processes. This again includes automation of boiler which demands
determination of certain physical parameters (pressure, temperature, level) & utilizing these
parameters to make the boiler start-stop or function in any manner we want, but

automatically, without involvement of any personal activity. The most common parameters
that have to be controlled in the boiler are temperature, pressure, water level. The controlling
mechanism can be achieved by using microprocessor and microcontroller, PID controller or
using PLC. Programmable logic control (PLC) provides an easy and sophisticated method to
design automation in industry. It also provides easy troubleshooting method and flexibility
to the industry. Generally an industry has an emergency stop button to stop the whole
process instantly if any error occurred during operation.
1.2 Objective of the thesis

The main objective of our thesis is to design a convenience and suitable industrial boiler
automation. To have such thing we need to do the following:
• To be familiar with PLC(programmable logic controller) software’s
• To reduce overall expenditure in terms of wages, wastage of material due to

inaccurate manual work and to reduce the overall time taken for production in
industries.
• To increase plant production efficiency
• Controlling boiler before damaging, controlling boiler from hazards
1.3 Significance of the project
• To measure the actual values of different parameters for which the boiler is designed.
• Safe working range of the different parameters is maintained.
• To monitor one or more variables at a time and provide input for automatic control.
• In case of operator failure to take remedial action for an upset condition, it protects
the boiler by alarms and trappings.
• To provide data on operating conditions before failure of the equipment for
analyzing the failure.

1.4 Scope of the project
Industrial boiler is a system designed to produce steam in varying quantities for a variety of
applications including space heating, process heating, power generation and other huge
industries. We know that boiler automation is a big system that can control everything
automatically in the large industry or power plants. But our project is specified for only five
systems due to the material requirement and time specified for the project.
• Level Control
• Pressure Control
• Flow Control
• Temperature Control
• DM pH monitor
Area of Expertise:
• Machine automation
• Chemical industries
• Tire building machinery
• Baneberry automation
• Refinery automation
• LPG bottling plant automation
• Printing and post-printing machineries
• Textiles machinery
• Water treatment projects
• PC-based automation
• Food processing
• Packaging
• Paper & Pulp industry
• Biomedical Instrumentation

1.5 Methodology
The method that we have used in this thesis is a programmable logic controller (PLC). Since
this programmable logic control is more applicable in industries as well as commercial
applications. To control the level, temperature, pressure, and flow sensor of the industrial
boiler automation precisely and within short period of time we can use this program. The
flow chart for this project development is expressed as:
Figure 1.5 over all block diagram of industrial boiler automation

1.6 overview of the thesis
Figure 1.6a overview of the thesis

Generally an industry has an emergency stop button to stop the whole process instantly if
any error occurred during operation. The emergency stop buttons are normally closed type.
To start the mechanism a start button (normally open type) switch is used which is
connected after stop button. When start button is made ON the lower level sensor sense the
water level below the lower level hence it start the motor to pump the water in to the boiler.
The pump runs till the water reaches the higher level sensor. After that the pump stops
running. The temperature sensor provides the temperature information to the PLC. If the
temperature is less than the present value the heater starts after 5 sec of motor OFF time.
Temperature rises continuously and form water steam. The temp should not rise beyond
tolerance level of boiler hence the temperature should rise up to certain limit and the heater
should stop at that moment. The temperature again decreases and if goes below preset value
it starts the heater. The above process continues. The steam produce in the boiler exert a
pressure on the boiler which is picked up by the pressure sensor. If pressure reaches the
present value it make the valve open and steam with a definite pressure goes out through the
pipe. The present value of the pressure should be calculated carefully and it should not

exceed maximum limit of boiler tolerance. This process result in decrease in water level and
if falls below the lower level sensor the motor starts during which the heater stops and
whole process repeats.
1.7 industrial boiler process block diagram
The above schematic over view of our project is described as follows in process block
diagram the most prominent being steam generation for utilities and power plant turbines.
The primary objective of a boiler is to achieve optimum operating efficiency with high
reliability and low cost. Techniques to improve boiler operation in the past decade have
largely focused on optimizing boiler performance while simultaneously adhering to
environmental constraints. Model predictive control (MPC) has become an increasingly
popular replacement for traditional boiler control and optimization. We provide boiler plant
for different industrial uses where this is counted as the most eminent requirement. Our
boiler plant automation is equipped with latest techniques and provides more prominent
results. Amongst the many industrial boiler plants manufacturer and exporters from India,
our company has proved itself as the major provider of boiler plant. In the past, boilers in an
industrial complex were considered a necessary evil. However today’s a business manager
know this is no longer the case? Boilers are required to maintain maximum steam generation
efficiency, maximum reliability, and comply with both stringent air emission and safety
regulations. To achieve this goal you need modern control hardware and software. In today’s
competitive market minimization or reduction of operating costs is a valid method to
increase profitability. Reducing fuel expenses associated with your boilers can directly
impact manufacturing costs. We have a full portfolio of solutions for the industrial power
house. Boiler control is the most commonly implemented solution. We have developed a
control system standard for coal-oil- and mixed-fuel-fired boilers, which allows the
expertise gained from the implementation of many of the boiler Control projects to be made
available to our customers.

Description
The Industrial Boiler Control solution implements the following major control strategies:
Steam Header Pressure Control
Combustion (Fuel Flow and Air Flow) Control
Furnace Pressure Control
Feed water/Drum Level Control
Superheat Temperature Control
Figure 1.6b industrial boiler process block diagram

1.7 Statement of the problem

Over the years the demand for high quality, greater efficiency and automated machines has
increased in the industrial sector of power plants. Power plants require continuous
monitoring and inspection at frequent intervals. There are possibilities of errors at measuring
and various stages involved with human workers and also the lack of few features of micro
controllers. Thus this paper takes a sincere attempt to explain advantages the companies will
face by implementing automation into them. The boiler control which is the most important
part of any power plant, and its automation is the precise effort of this paper. In order to
automate a power plant and minimize human intervention, there is a need to develop a PLC
that monitors the plant and helps reduce the errors caused by humans. PLC (Programmable
Logic Controller) is also used for the internal storage of instruction for the implementing
function such as logic, sequencing, timing, counting and arithmetic to control through digital
or analog input/ output modules various types of machine processes.
1.8 organization of the thesis
The project is organized into five main chapters that are interrelated to each other and these
are described as follows.
The first chapter describes the introduction part of the project includes background,
objectives, problem of statement, scope and methodology parts of the project.
The second chapter expresses about programmable logic controllers (PLC) that are used to
solve our project problems , components of PLC like power supply, processor, memory and
I/O modules, specification for PLCs, operations of PLC and programming method that is
ladder logic programming.
The third chapter describes the general component functions that are used within the
programmable logic controller. These are inputs like sensors and switches, outputs like
lamps actuators and pump motors, control and communication functions of the systems of
the boiler automation system.
The next chapter that is chapter four is about the main parts of systems that are to be
controlled in our thesis like level, pressure, temperature and PH. The last chapter that is
chapter five includes the design processes of the thesis like hardware’s design and software

design of the systems. This also describes the PLC types that are used for our design, ladder
logic programming of the systems and the final result, conclusion and recommendation of
our project.

CHAPTER TWO
2. Programmable Logic Controller
2.1 Introduction
Programmable logic controllers (PLCs) are members of the computer family capable
of storing instructions to control functions such as sequencing, timing, and counting, which
control machine or a process. The PLC is composed of two basic sections, the Central
Processing Unit (CPU) and the Input/output (I/O) interface system. The PLC measures input
signals coming from a machine and through the internal program provides output or control
back to the machine. Ladder logic is the programming language used to represent electrical
sequences of operation. In hardwired circuits the electrical wiring is connected from one
device to another according to logic of operation. In a PLC the devices are connected to the
input interface, the outputs are connected to the output interface and the actual wiring of the
components is done electronically inside the PLC using ladder logic. This is known as soft
wired. PLC is a device that is capable of being programmed to perform a controlling
function. Before the advent of PLC, the problem of industrial control was usually solved by
relays or hardwired solid-state logic blocks. These are very flexible in design and easy for
maintenance personal to understand. However, they involved vast amount of
interconnection. For the wiring cost to be minimized relays and logic blocks had to be kept
together. This led to development of control panel concept for larger and more complex
logic control system. The PLC was first conceived by group of engineers from hydrometric
division of GM in 1968.This was designed to provide flexibility in control based on
programming and executing logic instruction.
Advantages of PLC
PLCs have been gaining popularity on the factory floor and will probably remain
predominant for some time to come. Most of this is because of the following general
advantages they offer:

• Cost effective for controlling complex systems.

• Flexible and can be reapplied to control other systems quickly and easily.
• Computational abilities allow more sophisticated control.
• Troubleshooting aids make programming easier and reduce downtime.
• Reliable components make these likely to operate for years before failure.
• Smaller physical size than hard-wire solutions.
• Easier and faster to make changes.
• PLCs have integrated diagnostics and override functions.
• Diagnostics are centrally available.
• Applications can be immediately documented.
• Applications can be duplicated faster and less expensively
2.2. History of PLC
In the late 1960's PLCs were first introduced. The primary reason for designing such a
device was eliminating the large cost involved in replacing the complicated relay based
machine control systems. Bedford Associates (Bedford, MA) proposed something called a
Modular Digital Controller (MODICON) to a major US car manufacturer. Other companies
at the time proposed computer based schemes, one of which was based upon the PDP-8. The
MODICON 084 brought the world's first PLC into commercial production. When
production requirements changed so did the control system. This becomes very expensive
when the change is frequent. Since relays are mechanical devices they also have a limited
lifetime which required strict adhesion to maintenance schedules. Troubleshooting was also
quite tedious when so many relay are involved. Now picture a machine control panel that
included many, possibly hundreds or thousands, of individual relays. The size could be mind
boggling. How about the complicated initial wiring of so many individual devices! These
relays would be individually wired together in a manner that would yield the desired
outcome. These "new controllers" also had to be easily programmed by maintenance and
plant engineers. The life time had to be long and programming changes easily performed.
They also had to survive the harsh industrial environment. That's a lot to ask! The answers
were to use a programming technique most people were already familiar with and replace
mechanical parts with solid-state ones. The AMD 2901 and 2903 were quite popular in

Modicum and A-B PLCs. Conventional microprocessors lacked the power to quickly solve
PLC logic in all but the smallest PLCs. As conventional microprocessors evolved, larger and
larger PLCs were being based upon them. However, even today some are still based upon
the 2903. Madison has yet to build a faster PLC than their 984A/B/X which was based upon
the 2901.Communications abilities began to appear in approximately 1973. The first such
system was Madison’s Mudbug. The PLC could now talk to other PLCs and they could be
far away from the actual machine they were controlling. They could also now be used to
send and receive varying voltages to allow them to enter the analog world. Unfortunately,
the lack of standardization coupled with continually changing technology has made PLC
communications a nightmare of incompatible protocols and physical networks. Still, it was a
great decade for the PLC. The saw an attempt to standardize communications with general
Motor's manufacturing automation protocol (MAP). It was also a time for reducing the size
of the PLC and making them software programmable through symbolic programming on
personal computers instead of dedicated programming terminals or handheld programmers.
Today the world's smallest PLC is about the size of a single control relay. We have seen a
gradual reduction in the introduction of new protocols, and the modernization of the
physical layers of some of the more popular protocols that survived the1980's. The latest
standard (IEC 1131-3) has tried to merge PLC programming languages under one
international standard. We now have PLCs that are programmable in function
block diagrams, instruction lists, C and structured text all at the same time! PC's are also
being used to replace PLCs in some applications. The original company who commissioned
the MODICON084 has actually switched to a PC based control system.
2.3 Plc hardware

A programmable logic controller consists of the following components:-Central Processing
Unit (CPU), Memory, Input modules, Output modules and Power supply. APLC hardware
block diagram is shown in Figure. The programming terminal in the diagram is not a part of
the PLC, but it is essential to have a terminal for programming or monitoring a PLC. In the
diagram, the arrows between blocks indicate the information and power-flowing-direction.

Figure 2.3 plc hardware components and power flow direction
2.3.1 CPU:-
Like other computerized devices, there is a Central Processing Unit (CPU) in a PLC. The
CPU, which is the brain of a PLC, does the following operations:
• Updating inputs and outputs. This function allows a PLC to read the status of its
input terminals and energize or de-energize its output terminals.
• Performing logic and arithmetic operations. A CPU conducts all the mathematic
and logic operations involved in a PLC.
• Communicating with memory. The PLC conducts all programs and data are
stored in memory. When a PLC is operating, its CPU may read or change the
contents of memory locations.
• Scanning application programs. An application program, which is called a ladder
logic program, is a set of instructions written by a PLC programmer. The
scanning function allows the PLC to execute the application program as specified
by the programmer.
• Communicating with a programming terminal. The CPU transfers program and
data between itself and the programming terminal. A PLC CPU is controlled by
operating system software. The operating system software is a group of

supervisory programs that are loaded and stored permanently in the PLC memory
by the PLC manufacturer.
2.3.2 Memory:-
Memory is the component that stores information, programs, and data in a PLC. The process
of putting new information into a memory location is called writing. The process of
retrieving information from a memory location is called reading. The common types of
memory used in PLCs are Read Only Memory (ROM) and Random Access Memory
(RAM). A ROM location can be read, but not written. ROM is used to store programs and
data that should not be altered. For example, the PLCs operating programs are stored in
ROM.A RAM location can be read or written. This means the information stored in a RAM
location can be retrieved and/or altered. Ladder logic programs are stored in RAM. When a
new ladder logic program is loaded into a PLCs memory, the old program that was stored in
the same locations is over-written and essentially erased. The memory capacities of PLCs
vary. Memory capacities are often expressed in terms of kilo-bytes (K). One byte is a group
of 8 bits. One bit is a memory location that may store one binary number that has the value
of either 1 or 0. (Binary numbers are addressed in Module 2). 1K memory means that there
are 1024 bytes of RAM. 16K memory means there are 16 x 1024 =16384 bytes of RAM.
2.3.3 Input modules and output modules:-

A PLC is a control device. It takes information from inputs and makes decisions to energize
or de-energize outputs. The decisions are made based on the statuses of inputs and outputs
and the ladder logic program that is being executed. The input devices used with a PLC
include pushbuttons, limit switches, relay contacts, photo sensors, proximity switches,
temperature sensors, and the like. These input devices can be AC (alternating current) or DC
(direct current). The input voltages can be high or low. The input signals can be digital
or analog. Differing inputs require different input modules. An input module provides an
interface between input devices and a PLCs CPU, which uses only a low DC voltage. The
input module function is to convert the input signals to DC voltages that are acceptable to
the CPU. Standard discrete input modules include 24 V AC, 48 V AC, 120 V AC, 220 V
AC, 24 VDC, 48 V DC, 120 V DC, 220 V DC, and transistor-transistor logic (TTL) level.
The devices controlled by a PLC include relays, alarms, solenoids, fans, lights, and

motor starters. These devices may require different levels of AC or DC voltages. Since the
signals processed in a PLC are low DC voltages, it is the function of the output module to
convert PLC control signals to the voltages required by the controlled circuits or devices.
Standard discrete output modules include 24 V AC, 48 V AC, 120 V AC, 220 V AC, 24 V
DC, 48 V DC, 120 VDC, 220 V DC, and TTL level.
Power Supply:-
PLCs are powered by standard commercial AC power lines. However, many PLC
components, such as the CPU and memory, utilize 5 volts or another level of DC power. The
PLC power supply converts AC power into DC power to support those components of the
PLC.
2.3.4 Programming Terminal:-

A PLC requires a programming terminal and programming software for operation. The
programming terminal can be a dedicated terminal or a generic computer purchased
anywhere. The programming terminal is used for programming the PLC and monitoring the
PLC operation. It may also download a ladder logic program (the sending of a program from
the programming terminal to the PLC) or upload a ladder logic program (the sending of a
program from the PLC to the programming terminal). The terminal uses programming
software for programming and talking to a PLC.
2.3.5 Signal modules

The signal modules of PLC include:
• Digital Input (DI)
• Digital Output (DO)
• Analog Input (AI)
• Analog Output (AO)
2.4 Programming device:

In recent years programmable logic devices (PLDs) have all but replaced special-purpose
logic devices such as AND gates, flip-flops, counters, multiplexers, etc. PLDs are chips that
can be programmed, and often re-programmed, to implement different logic functions. The
main reason for using programmable logic is to reduce total costs. This is due to a number of

reasons: One important advantage is that design with PLDs is faster and this reduces the
time required to bring a product to market. Programmable devices also reduce the risks
associated with product development since they allow last-minute changes, often without
having to redesign circuit boards. Since PLDs often replace several other special-purpose
devices the design usually has fewer components and this reduces PCB, assembly, and test
repair costs. Using PLDs also means fewer parts needs to be stocked and this reduces
inventory costs. Since more of the logic is integrated into each chip the number of
interconnections is decreased and this increases the reliability of the product.
Classifications of Simple Programmable Logic Devices (SPLD)
• Programmable Read-Only Memory (PROM)
• Programmable Logic Array (PLA)
• Programmable Array Logic (PAL)
• Generic Array Logic (GAL)
Programmable Read-Only Memory (PROM)
The PROM is used primarily as an addressable memory and not as logic device because of
limitations imposed by fixed AND gates.
Programmable Logic Array (PLA)
The PLA was developed to overcome some of the limitations of PROM. The PLA is also
called an FPLA (Field programmable logic array) because the user in the field, not the
manufacturer, programs it. It was developed to overcome certain disadvantages of PLA,
such as longer delays due to the additional fusible links that result from using two
programmable arrays and more difficult complexity.
Programmable Array Logic (PAL)
The PAL is most common one-time programmable (OTP) logic device and is implemented
with bipolar technology (TTL or ECL).
Generic Array Logic (GAL)
The two main differences between GAL and PAL devices are:
• The GAL is reprogrammable
• The GAL has programmable output configurations.

• The GAL programmable again and again because it uses E2CMOS

(electrically erasable CMOS) technology instead of bipolar technology and
fusible links.
2.5 Specifications to use PLC

The factors we are used for selecting, evaluating the quality and performance of
programmable controllers for our project is due to some of the following.
• Low cost
• Software availability
• Memory capacity
• Number of I /O ports
• Simplicity to use the software
Specifically we are going to select semantics LOGO! Soft comfort software for our project
due to:
• Easy and quick configuration. This allows the creation of ladder and function
block diagrams by selecting the respective functions and their connection via
drag & drop.
• The entire switching program can be simulated and tested offline on the PC.
• Last but not least, LOGO! Soft Comfort provides professional documentation
with all of the necessary project information such as switching programs,
comments, and parameter settings.
• Also possible: an online test in both program displays during operation.
2.6 working of plc:-

First we need bringing input signal status to the internal memory of CPU. The field signals
are connected to the I/P module. At the output of I/P module the field status converted into
the voltage level required by the CPU is always available. At the beginning of each cycle the
CPU brings in all the field I/P signals from me/P module &stores into its internal memory
called as PII, meaning process image input. The programmable controller operates cyclically

meaning when complete program has been scanned; it starts again at the beginning of the
program.
I/O BUS:-A PLC works by continually scanning a program. We can think of this scan cycle
as consisting of 3 important steps. There are typically more than 3 but we can focus on the
important parts and not worry about the others. Typically the others are checking the system
and updating the current internal counter and timer values.
Step 1-Check Input Status-First the PLC takes a look at each input to determine if it is on or
off. In other words, is the sensor connected to the first input on How about the second input
How about the third... It records this data into its memory to be used during the next step.
Step 2-Execute Program-Next the PLC executes your program one instruction at a time.
May be your program said that if the first input was on then it should turn on the first output.
Since it already knows which inputs are on/off from the previous step it will be able to
decide whether the first output should be turned on based on the state of the first input. It
will store the execution results for use later during the next step
Step 3-Update Output Status-Finally the PLC updates the status of the outputs. It updates
the outputs based on which inputs were on during the first step and the results of executing
your program during the second step. Based on the example in step 2 it would now turn on
the first output because the first input was on and our program said to turn on the first output
when this condition is true.

Plc. switched into “run”
Figure 2.6 PLC operational cycle flow chart

From the above flow chart each PLC operational cycle is made up of three separate parts:
• Input scan at which input terminals are read and the input status table is updated.
• Program scan at which data in the input status table is applied to the user program,
the program is executed and the output status table is executed.
• Output scan at which data associated with the output status table is transferred to
output terminals

2.7 Programming of the PLC
The concept of controlling of a control system is simple and easy task with PLC as
compared other controlling systems. It involves a systematic approach by the following the
operation procedure.
1. Determine the process sequence of operation

Firstly, we have to decide what equipment or system we want to control. The
ultimate purpose of programmable controller is to control an external system. This
system to be controlled can be a machine equipment or process and is often
generically called the control system. The movement of the controlled system is
constantly monitored by the input devices that give a specified condition and send a
signal to the PLC. In response, the PLC outputs a signal to the external output
devices which actually controls the movement of the controlled system as specified
and thus achieves the extended control system. In simplicity we need to determine
the sequence of the operation by drawing out the flowchart.
2. Assignment of inputs and outputs
Secondly, all external input and output devices to be connected to PLC must be
determined. The input devices are various switches, sensors, etc. and the outputs
devices are the solenoids, valves ,motor inductors etc. after identifying all various i/o
devices, assigned the numbers corresponding to the input and output number of the
particular PLC we will be using. The actual wiring will follow the numbers of the
PLC .the Assignment of inputs and outputs numbers must be carried before wiring
the ladder diagram because the number indicate what is the prices meaning of the
contacts in the ladder diagram.
3. Writing the program
Next, we need to write the program by the following the control system sequence of
the operation as determined by step one.
4. Programming into memory
Now, we can apply power to PLC depending on the type of pc we may have to do I/p
generation to prepare the system configuration. After that, we can enter our program

in to memory either by programming console or by computer aided ladder software

tool. After completion of the programming, we should check for any coding errors
by means of diagnostics Function, and if possible simulate the whole operation to see
that it is alright our program.
5. Running the system:
Before the start pushbutton is pressed, thoroughly ensure that the input and output
wiring are correctly connected according to the I/P assignment. Once confirmed, the
actual operation of the PLC can now be started. You may need to debug along the
way and fine tune the control system if necessary. Test run thoroughly until it is safe
to operate by any one.

Figure 2.7 Programming PLC steps flow chart

Three common types of PLC programming languages:
• Ladder logic
• Statement lists
• Function block diagrams
Ladder logic:
Ladder diagram is kind of graphical programming language that changed the relay control
wiring circuit diagram. In order to allow established relay logic users to program the PLC, a
visual programming language that looks like a relay control panel was created.
Ladder logic uses graphic symbols similar to relay schematic circuit diagrams.
Ladder diagram consists of two vertical lines representing the power rails. Circuits are connected as
horizontal lines between these two verticals.
Ladder diagram features

• Power flows from left to right.
• Output on right side cannot be connected directly with left side.
• Contact cannot be placed on the right of output.
• Each rung contains one output at least.
• Each output can be used only once in the program.
• A particular input a/o output can appear in more than one rung of a ladder.
• The inputs a/o outputs are all identified by their addresses, the notation used
depending on the PLC manufacturer.
Statement lists:
Statement list is a programming language using mnemonic abbreviations of Boolean

logic operations. Boolean operations work on combination of variables that are true or false.
A statement is an instruction or directive for the PLC.
Statement List Operations
• Load (LD) instruction.

• And (A) instruction.

• ALD: and the first load the second
Output (=) instruction.

FunctionBlockDiagrams:
Function block is represented as a box with the function name written in. Those
programming language can be compared and related as follows in table
Table 1 comparison of plc program types
Programm Ladder diagram Functional block Statement list

ing diagram
language
AND
OR
Feedback

CHAPTER THREE
3. Function of components used for our thesis work

In industrial boiler automation is mainly applicable in many types of industries and power
generations. Due to this reason we should to control components of the boiler automatically.
3.1. Input components
3.1.1. Switches
Switches are the basic components of PLC. Two types of switches are available in plc.
i. Digital switch (ON/OFF).
ii. Analog switches (continuous varying).
I) digital switch
Two type of states are available under digital type i.e. NO (normally open) or NC (normally
Closed)
Normally open:
A switch is said to be normally open when it doesn’t allow current to pass till it is off. When
the switch is made on by applying appropriate voltage, in case of PLC, it allows current to
pass and actuate the coil or component attached to it. NO switches are used when we
required no current till we made the switch ON and again it can be made OFF by removing
voltage source from the respective switch. A NO switch is represented as following symbol.
Figure 3.1 normally open switch

Normally closed:
A switch is said to be normally closed when at off condition (i.e. when voltage is not applied
to the switch in PLC) is act as closed that is it allows the current to flow through it. When
the voltage is applied to the switch it becomes open circuited. These types of switches are
normally used when we need current at the coil in absence of input voltage. Example is

emergency off switches which need to be on initially and should be off when switch is
pressed.
Figure 3.1.1 normally closed switch

In PLC point of view the transition from ON to OFF or OFF to ON be done by applying
24VDC to the respective switch. The following diagram shows the switches ON and OFF
conditions and OFF refers to withdraw of supply.
• In PLC BLUE at center of switch of both NO and NC represent close circuit of
switch and absent of color indicates open circuit.
• In Logo PLC the number of digital switch is 24.
II) Analog switch
As the name indicates the analog switches are continuously varying switches. These
switches are the combination of sensor output and comparator circuit. Analog switches are
used when a device (heater, valve) has to be turned on or off with respect to the set value of
continuously varying parameters (temperature, pressure etc.).
Working principle:
It is the series combination of sensor output and comparator circuit. The continuously
varying parameter is measured and the conditioned output is provided to the comparator
whose one set point is provided previously by programmer. As per the sensor output
comparator gives output + VCC or VEE (ON/OFF). The diagram bellow represents the
normal notation of temperature regulated analog switch and analog switch define by Logo
software.
There are two analog switches in the Logo PLC. One varies with current (0 to 20 mA),
switch number ‘D4980’ and other varies with voltage (0 to 10 V), switch number
‘D4981’.Adjusting the set point:

The range of analog input variable linearly varies from 0-4000 units, in which for voltage
change it varies from 0-10 volts and in case of current circuit it varies from 0-20mA. 4000 is
analogous to 10 volts in voltage circuit and 20mA in case of a current circuit.
3.1.2. Timer
Timer is the electronics device which introduced delay in the circuit. In analog timers, when
the supply is given it start its countdown from a preset value set by the user. When the
countdown reaches zero the output of timer becomes high. An analog timer uses the IC 555
forts operation. Analog timer only provides delay after the supply is given to it but timers in
PLC provide more flexibility to the programmer. Following types of timers are available in
PLC
1. On delay – countdown starts when supply is ON and timer is ON when countdown
becomes zero. If timer is made OFF output is OFF.
2. Off delay – Timer is ON when the supply is ON and countdown start when the supply is
made OFF and timer is OFF when countdown reaches zero.
3. Retentive timer – It is same as ON delay timer except that once the output is ON by the
timer switching OFF the timer does not affect the output. To OFF the output the timer
should be reset by setting high the reset switch.
4. Pulse timer – Output is ON as soon as the timer is ON and countdown starts. As soon as
the timer reaches zero output becomes OFF. Any timer is OFF output becomes OFF.
5. Extended pulse timer – It is same as pulse timer but if once the timer is ON countdown
starts OFF of the supply doesn’t affect the output.
Siemens software provides ON& OFF delay type of timer from above list. To insert a timer
to the ladder diagram following procedure must be followed.
3.1.3 Sensors
Sensors are devices that convert a physical condition into an electrical signal for use by a
controller, such as a PLC. Sensors are connected to the input of a PLC. A pushbutton is one
example of a sensor. An electrical signal is sent from the pushbutton to the PLC indicating
the condition (open/close) of the push button contacts. Some examples of sensors are:
• PIR sensor
• Level sensor

• Flow sensor
• Temperature sensor
• Pressure sensor
• Smoke detector
• Heat sensor
• PH sensor
• Photo sensor etc.
Among the above sensors we are using for our thesis the following sensors
• Level sensor
• Flow sensor
• Temperature sensor
• Pressure sensor
• Smoke detector
• PH sensor
• Oxygen sensor
Level sensor
A low-energy float within these sensors measures liquid level at a certain point. Consisting
of a field-mounted sensor and integral solid state amplifier, contact float have moving parts.
Typically, they are equipped with terminal blocks for connection of a power source and
external control devices. The float crosses a one-half inch gap in the sensor, controlling
relay switches when the gap contains liquid. The sensing level is midway along the gap for
horizontally mounted sensors, at the top of the gap for vertically mounted sensors. These
sensors are used in vessels or pipes to automatically operate pumps, solenoid valves, and
high/low alarms. Two would be required to fill and empty tanks, and to meter liquid
volumes. Compatible with most liquids, they are unaffected by coatings, clinging droplets,
foam, and vapor. However, highly aerated liquids and liquids viscous enough to clog the
sensor gap may cause problems.
Steam boilers are very common in industry, principally because steam power is so useful.
Common uses for steam in industry include doing mechanical work (e.g. a steam engine
moving some sort of machine), heating, producing vacuums through the use of steam, and

augmenting chemical processes (e.g. reforming of natural gas into hydrogen and carbon
dioxide).
The process of converting water into steam is quite simple: heat up the water until it boils.
Anyone who has ever boiled a pot of water for cooking knows how this process works.
Making steam continuously, however, is a little more complicated. An important variable to
measure and control in a continuous boiler is the level of water in the “steam drum” (the
upper vessel in a water-tube boiler). In order to safely and efficiently produce a continuous
flow of steam, we must ensure the steam drum never runs too low on water, or too high. If
there is not enough water in the drum, the water tubes may run dry and burn through from
the heat of the fire. If there is too much water in the drum, liquid water may be carried along
with the flow of steam, causing problems downstream.
In this next illustration, you can see the essential elements of a water level control system,
showing transmitter, controller, and control valve. The purpose of this device is to sense the
water level in the steam drum and report that measurement to the controller in the form of an
instrument signal. In this case, the type of signal is pneumatic: a variable air pressure sent
through metal or plastic tubes. The greater the water level in the drum, the more air pressure
output by the level transmitter. Since the transmitter is pneumatic, it must be supplied with a
source of clean, compressed air on which to run. This is the meaning of the “A.S.” tube (Air
Supply) entering the top of the transmitter. A human operator running this boiler has the
option of placing the controller into “manual” mode. In this mode, the control valve position
is under direct control of the human operator, with the controller essentially ignoring the
signal sent from the water level transmitter. Being an indicating controller, the controller
faceplate will still show how much water is in the steam drum, but it is now the human
operator’s sole responsibility to move the control valve to the appropriate position to hold
water level at set point.
Level control system: The raw water from any source is to be injected in to the main process
boiler tanker. This is achieved by sensing level of water in the boiler by the level sensor up
on sensing a low level, water injection is started with the help of water pump through the
solenoid valve. The control mechanism is shown below in the bock diagram.

Figure 3.1.3.1 Fig water injection of control system
This can be illustrated more in the figure below. The operation of the diagram below is:
When the liquid level is high pump is off and the lamp (alarm) is on when the liquid level is
low pump is on.
Figure 3.1.3.2 schematic diagram of pump moor and level sensor

PH sensor:
The main objective of PH sensor is to detect the water whether it has an acidity or base
content. Because a specified or limited amount of acid and base is necessary for every
industry, commercial, medical, and for all living things. In this case the level senses the
value of acidity and base content. If the acidity or base content is above or below the set
value the alarm starts to sound. The controlling device for PH sensor can be interfaced to
PLC as shown below
Figure ph sensor block diagram
PH control system: in this case our main agenda is to maintain PH factor of water by
controlling the addition of base or acid in the main process tank through acid &base valves.
This sensor will detect the PH of water & passes the PH value to PLC after the specified
time. The controlling system of PH sensor is illustrated in the block diagram below:

Figure 3.1.3.4 PH sensor control block diagram
Temperature sensor:
This type of sensor is used to sense the temperature value of the industrial boiler automation
by compare and contrast the set point with the measured value of the system. For our thesis
resistance temperature detector RTDs is used for short, is wire wound and thin film devices
that measure temperature because of the physical principle of the positive temperature
coefficient of electrical resistance of metals. The hotter they become, the larger or higher the
value of their electrical resistance. In this thesis we have been used to that PRT100 type of
temperature sensor.PRT100 is most popular RTD type, nearly linear over a wide range
temperature and some small enough to have response times of a fraction of second. The lead
wires used to connect the RTD to read can contribute to their measurement error, especially
when there are long lead lengths involved, as often happens in remote temperature
measurement locations. Those calculations are straight forward and there exist 3-wire and 4-
wire designs to help minimize or limit such errors, when needed. Often the lead error can be
minimized through use of a temperature transmitter mounted close to the RTD. Transmitters
convert the resistance measurement to an analog current or serial signal that can be sent long
distances by wire to a data acquisition or control system and indicator.

Flow sensor:
Flow meters are related to devices called velocimeters that measure velocity of fluids
flowing through them. Laser-based interferometer is often used for air flow measurement,
but for liquids, it is often easier to measure the flow. Another approach is Doppler-based
methods for flow measurement. Flow sensor is used to sense the travelling or flowing of the
fluid from the environment to the main system and also regarded as fast loops that respond
to change quickly. Therefore, flow control equipment must have fast sampling and response
times. Because flow transmitters tend to be rather sensitive devises, they can produce rapid
fluctuations or noise in the control signal. To compensate for noise, many flow transmitters
have a damping function that filters out noise. Filters are added between the transmitter and
the control system. Because the temperature of the process fluid affects its, density,
temperature measurements are often taken with flow measurements and compensation for
temperature is accounted for in the flow calculation. There are many applications in which it
is desirable to connect one or more flow sensors to a PLC (programmable logic controller),
and the flow sensors are well suited for this. In many cases the digital pulse of a flow sensor
can be connected directly, or with a minimum of components.
The flow sensors most commonly chosen for use with a PLC are EX series and TX series
insertion flow sensors. These flow sensors, which have three wires, use Hall-effect
technology. They need 5-24 Volts DC and up to 8am current and they are current sinking
(NPN) devices. The flow sensors can connect directly to the PLC if:
• The flow sensor power on the PLC is 5 - 24 VDC (VDC is typical.)

• The flow sensor power supply can provide at least 6 am (100 is typical.)
The flow sensor input on the PLC can accept a current sinking device. If the PLC input only
accepts current sourcing devices, a pull-up resistor must be added to allow the flow sensor to
work correctly. Connection of this resistor is shown below. Typically, on a 24 VDC input a
2.2 K Ohm resistor will be effective.
Control system of flow sensor is takes place by controlling of all parameters by using PLC
in order to obtain suitable feedback to the boiler system. Since all the inputs are read from

tank, valve, pressure, temperature, density and pump motor which is supplied to the
program. Then this program will be executed according to the desired or set point.
Figure 3.1.3.5 block diagram of flow control system
Pressure sensor:
Piezoresistive strain gauge
In our thesis we select this type of sensor to sense the pressure in entire of the system. The
piezoresistive effect of bonded or formed strain gauges to detect strain due to applied
pressure. Common technology types are Silicon (Monocrystalline), Polysilicon Thin Film,
Bonded Metal Foil, Thick Film, and Sputtered Thin Film. Generally, the strain gauges are
connected to form a Wheatstone bridge circuit to maximize the output of the sensor and to
reduce sensitivity to errors. This is the most commonly employed sensing technology for
general purpose pressure measurement. Generally, these technologies are suited to measure
absolute, gauge, vacuum, and differential pressures.

All masses require force to accelerate (we can also think of this in terms of the mass
generating abreaction force as a result of being accelerated). This is quantitatively expressed
by Newton's Second Law of Motion:
F MA
All fluids possess mass, and therefore require force to accelerate just like solid masses. If we
consider a quantity of fluid confined inside a pipe with that fluid quantity having a mass
equal to its volume multiplied by its mass density (M 1/2V, where 1/2 is the fluid's mass
per unit volume), the force required to accelerate that fluid would be calculated just the
same as for a solid mass:
Smoke detector:
A smoke detector is a device that detects smoke, typically as an indicator of fire.
Commercial, industrial, and mass residential devices issue a signal to a fire alarm system,
while household detectors, known as smoke alarms, generally issue a local audible or visual
alarm from the detector itself. Most smoke detectors work either by optical detection
(photoelectric) or by physical process (ionization), while others use both detection methods
to increase sensitivity to smoke. Sensitive alarms can be used to detect, and thus detector,
smoking in areas where it is banned such as toilets and schools. Smoke detectors in large
commercial, industrial, and residential buildings are usually powered by a central fire alarm
system, which is powered by the building power with a battery backup. However, in many
single family detached and smaller multiple family housings, a smoke alarm is often
powered only by a single disposable battery.
Oxygen sensor:
Oxygen sensor is used to sense or manage the excess of the amount of oxygen content in the
heater which is used to compare and contrast with the set point for highly efficient
combustion. In our thesis we use oxygen analyzers for improved measurement accuracy and
repeatability; users are also demanding analyzers that require a minimum of maintenance
and calibration. The oxygen sensor is a stand-alone, closed-loop control system that
measures flue gas excess oxygen and constantly adjusts fuel flow to achieve a user-
selectable set point. An electronic sensor is inserted into the boiler flue, near the boiler,

ahead of any dampers or other sources of air leakage into the boiler or flue. The sensor is
connected to a control panel that measures oxygen and sends a signal to a control damper on
the burner air supply.
Figure 3.1.3.6 components of oxygen sensor
3.2 output components:

PLC Outputs are the control circuits of the PLC and also refers to the devices controlled by
the PLC. Be aware when talking about PLCs the devices like motors and lights are also
referred to as PLC Outputs. Devices called actuators convert the electrical signal of the PLC
to a physical movement for instance a valve solenoid stoke or a motor contactor. With
regards to the variable output, the I/P (current to pneumatic) actuator, is an example. Some
of the outputs

3.2.1 Water pump:
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 boiler’s 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
maximum pressure.
3.2.2 Solenoid valve
A solenoid valve is an electromechanical valve for use with liquid or gas. The valve is
controlled by an electric current through a solenoid: in the case of a two-port valve the flow
is switched on or off; in the case of a three-port valve, the outflow is switched between the
two outlet ports. Multiple solenoid valves can be placed together on a manifold. Solenoid
valves are the most frequently used control elements in fluidics. Their tasks are to shutoff,
release, and dose, distribute or mix fluids. They are found in many application areas.
Solenoids offer fast and safe switching, high reliability, long service life, good medium
compatibility of them arterials used, low control power and compact design. Besides the
plunger-type actuator which is used most frequently, pivoted-armature actuators and rocker
actuators are also used.
Figure 3.2.2 solenoid valve

3.2.3 Buzzer:
A Buzzer or beeper is an audio signaling device. Typical uses of buzzers and beepers
include alarms, timers and confirmation of user input such as a mouse click or keystroke.
Types of buzzer:
• Mechanical
• Electromechanical
• Piezoelectric
1. Mechanical:
A joy buzzer is an example of a purely mechanical buzzer.
2. Electro mechanical:
Early devices were based on an electromechanical system identical to an electric bell
without the metal gong. Similarly, a relay may be connected to interrupt its own
actuating current, causing the contacts to buzz. Often these units were anchored to a
wall or ceiling to use it as a sounding board. The word "buzzer" comes from the
rasping noise that electro mechanical buzzers made.
3. Piezoelectric:
A piezoelectric element may be driven by an oscillating electronic circuit or other
audio signal source, driven with a piezoelectric audio amplifier. Sounds commonly
used to indicate that a button has been pressed are a click, a ring or a beep.
In our project we are used the Electromechanical type of buzzer due to their specifications
and futures.
• Low frequency tone (2 kHz).

• Suitable for automatic radial taping machine(15mm-pitch)
• Sound pressure:70dBA,10cm min.[at 2kHz, 5V0-P rectangular wave,
• Measuring temperature: 25±5°C, humidity: 60±10%].
• Temperature range:
• Operating ±20 to +70°C
• Storage ±30 to +80°C.
• Maximum input voltage 30V max. [Without DC bias].

3.2.4 Relays
• In General, Relays Transform a Control Signal into a Control Action
• Relays Provide:
– Isolation Between Input and Output
– Leverage (Small Signal Can Control Large Action)
– Automation (Minimize Human Interaction with a Control Process)
Relay Components:
Figure 3.2.4 Relay Components
• Relays can be designed to Perform Many Functions
– Detect Out of Limit Conditions on Voltages and Currents

– Start Motors
– Prevent Motors from Over Heating
– Control Assembly Line
– Adjust Lighting

3.3 Communication of the plc

When you come to a set of traffic lights, you observe the color and interpret red as meaning
stop and green as go. In Britain we also have orange which gives a warning of change but it
does not take priority over stop or go. This is protocol and other countries have a different
protocol so we must be very careful to use the correct protocol. Another example of protocol
is shaking the head to mean no and nodding to mean yes. There are countries where the
opposite applies.
When you use a computer or mobile phone to communicate with someone else, the data is
transmitted digitally. Each end of the communication link has a MODEM
(Modulator/Demodulator) to encode or decode the digital data. The transmission may be
through a radio link, through copper wires or optic fibers.
More complex systems such as used in industry or at a telephone exchange, send multiple
channels in both directions and in order to do this they need a multiplexer. When sending
data the multiplexer mixes the channels together to form one channel. The modem sends
them (a bit of each at a time). When receiving signals, the process is reversed. Signals are
needed to tell the equipment when to send and when to receive. Other signals are needed to
synchronies the signals at both ends. This is another example of protocol. On electronic
equipment we find many types of standard plugs and sockets. Here are 3 popular types.
These are used typically on printers, scanners, disc drives and COM ports. They may be
attached to all forms of industrial equipment as well as computers. Some carry SERIAL
transmission and other PARALLEL transmission. Serial transmission means the data is sent
one bit at a time while parallel transmission might send a whole word in one go. Digital data
transmission is not covered in detail here.

Figure 3.3a connecting plugs

Industrial systems also use many methods of linking equipment such as PLCs, computers,
sensors, monitors and automated machinery. In order that equipment can be interconnected
physically, the sockets, plugs and wiring connections must be the same for everyone
otherwise you could not work with each other. The standards covering a range of sizes and
applications are numerous. Here are details of some of the standard forms of links and
protocols.
RS232
RS-232 is a system originally developed for linking tally printers and is a relatively slow
serial data transmission system. The standard is for the physical interface and protocol used
in many links from computers to industrial electronic equipment. The system has undergone
many updates and RS232C is the current one. Typical uses are in computer modems and
linking any device using serial communication. Somewhere in the equipment is a Universal
Asynchronous Receiver/Transmitter (UART) chip. The data is transmitted to a modem (or
other serial device) from its Data Terminal Equipment (DTE) interface. Data inside
equipment flows along busses (Data and Address busses) and these are parallel circuits.
Serial devices can only handle one bit at a time. The UART chip converts the groups of bits
in parallel to a serial stream of bits. The 9 pin (DB9) and 25 pin (DB25) sockets are shown
below with their connections for RS 232.

Figure 3.3b connecting pins
RS422
The RS422 is similar to the RS232 but it more suited to transmissions over long cables.
Converters are devices which allow different systems such as the RS232 and 422 to
communicate even though the protocols are different.
IEEE 488
This is the main standard for parallel data transmission such as used on the printer ports
(LPT) of computers. Usually you find the DB25 at the computer end and the electronics type
(36 pins) at the other end. These are widely used to link industrial equipment using digital
technology. When the electronics parallel interface was first developed, the main peripheral
was the printer. Since then, portable disk drives, tape backup drives, and CD-ROM players
are among devices that have adopted the parallel interface. These new uses caused
manufacturers to look at new ways to make the electronics parallel interface better. In 1991,
Lexmark, IBM, Texas instruments, and others met to discuss a standard that would offer
more speed and bi-directional communication. Their effort and the sponsorship of the IEEE
resulted in the IEEE 1284 committee. The IEEE 1284 standard was approved for release in
March, 1994.
There are various protocols and standards laying down the way they communicate such as:
ISO: International Standards Organization
IEEE: Institute of Electrical and Electronic Engineers
MAP: Manufacturing Automation Protocols.

This is a token-passing local area network configuration adopted by General Motors
for factory automation.
NETWORK- Definitions
LAN: Local Area Network
Ethernet: This is a very common method of networking computers in a LAN using copper
cabling. Ethernet will handle about 10,000,000 bits-per-second and can be used with almost
any kind of computer.
Intranet: This is a general name for networks linking computers within a private
organization such as colleges, businesses and government departments. They use standard
network technologies like Ethernet and web servers. Users connected to the intranet often
have access to the internet but a firewall prevents external users accessing it. Sometimes it
may allow access to an extranet to provide controlled access to some outsiders (e.g. other
government departments).
Extranet: An extranet is a private network that allows limited access to specified users. It
uses the Internet for these links. A typical example is a bank with internet access for
customers using secure protocols.
Programming Device Cable
A special cable, referred to as a PC/PPI cable, is needed when a personal computer is used
as a programming device. This cable allows the serial interface of the PLC to communicate
with the RS-232 serial interface of a personal computer. DIP switches on the PC/PPI cable
are used to select an appropriate speed (baud rate) at which information is passed between
the PLC and the computer.

Common Standards
RS -232
• Used in short-distance computer communications, with the majority of computer

hardware and peripherals.
• Has a maximum effective distance of approx. 30 m at 9600 baud.
Local Area Network (LAN)
• Local Area Network provides a physical link between all devices plus providing
overall data exchange management or protocol, ensuring that each device can “talk”
to other machines and understand data received from them.
• LANs provide the common, high-speed data communications bus which

interconnects any or all devices within the local area.
• LANs are commonly used in business applications to allow several users to share
costly software packages and peripheral equipment such as printers and hard disk
storage
RS- 422 / RS- 485
• Used for longer-distance links, often between several PCs in a distributed system.
• RS-485 can have a maximum distance of about 1000 meters.

CHAPTER FOUR
4. Plc based industrial boiler automation
4.1 software system design

Due to no or limited availability of the hardware parts of plc the hard ware design is left as
optional.
4.1.1. Software design process

The concept of controlling a control system is very simple and easy task it involves systematic
approach by following operation procedure.
Step1: Determine the system sequence of operation.
Step2: Assignment of Inputs and outputs
Step3: Writing of the program
Step4: Programming into Memory
Step5: Running the system and simulate
We start the programming structure by developing flow charts for each sensor we use as
follows.

Level sensor controller flowchart
Figure 4.1.1 level sensor controller flow chart

Temperature sensor controller flowchart
Figure 4.1.1.2 temperature sensor controller flowchart

PH sensor controller flowchart
Figure 4.1.1.3 PH sensor controller flowchart

Fire sensor in boiler automation
Figure 4.1.1.4 Fire sensor in boiler automation flow chart

Pressure sensor controller flow chart
Figure4.1.1.5 pressure sensor controller flow chart

Flow sensor controller flowchart
Figure 4.1.1.6 Flow sensor controller flowchart

Flowchart for oxygen sensor
Figure 4.1.1.7 Flowchart for oxygen sensor

Figure 4.1.1.8 over all flow chart

The above flow chart can be simplified in blocks as follows
Oxygen sensor
Fire sensor PLC
PH
sensor Input/out put module
Level
sensor
Water tank
Tempera pressur
ture e
sensor
valve Flow motor

sensor
Figure 4.1.1.9 simplified over all flow chart

Over all flow chart description

All industries use push button for switch ON and OFF purpose. As push button provides
momentary contact thus a concept of latching comes under play. In the concept of latching
the NO switch of the memory or coil is connected parallel to the NO switch of the push
button. So that when momentary contact is made the current flows to the coil and the coil
switch become NC providing a parallel path to current, though the push button is released
the output doesn’t OFF. An emergency push button has to be provided before the earlier
bush button which is a NC provides supply till it is not pressed. Once emergency push
button is pressed it discontinue the supply to the coil and the coil switch change its status to
NO so the whole system shutdown. At the beginning an emergency stop push button and a
start push button with latching is used for turn on and turn off the whole system. As per the
flow diagram the pump should be made on when water level sensor does not sense water
and the pump should made on for 50 seconds more after level sensor sense water. If during
turn on of the system, the sensor sense water the pump does not start. The motor starts only
if the water is below level sensor. For above logic a NC of the level switch is connected to15
the motor coil. Again same NC switch of level sensor is connected to an OFF TIMER of
delay 50 seconds. The NO of timer switch is connected parallel to pump coil. So when level
sensor doesn’t sense water due to NC contact of level switch the pump coil is actuated. So
output of 24V DC is generated from output port which is used to run a pump through relay.
Due to increase in water level at a time water will reach the level sensor and 24 V appear at
the input port which make NO of the level switch but a off timer is connected so that it delay
the off of the timer switch connected parallel to pump coil. So the pump will run for more 50
milliseconds. As the timer expired, the timer switch turned off causing the pump to turn off
through relay. The flow diagram shows that the heater should turn on 5 seconds after the
pump is off for safety purpose. An also the temperature should in between 90 to 110 degree
(sufficient to form steam) and water level should above level sensor. As temperature is
continuous varying parameter the output of temperature sensor is connected to PLC analog
input port. We select the current port as LM35; the temperature sensor varies linearly with
current. One analog switch with lower limit and other switch of same name but with upper
set point is connected differently to two memory coils. NO of lower set point switch and NC

of upper set point switch is connected to heater coil. So that when sensor sense temperature
less then lower value NO of memory switch change its state while NC of upper set point
provide the current continuity. While the upper set point is reached the memory coil is
actuated and the NC of memory switch becomes NO and it discontinues the connection.
Mean while the NC of an off timer connected to pump output is connected series to the
heater coil. A NO of the level switch conform water is available. A protection switch NC is
connected to sudden turn off of the heater. A memory coil is connected to the protection
switch and a recovery switch NO is connected parallel to memory coil and the memory
switch is connected series to the heater coil. So a lot of protection should be taken before
connection. The pressure valve is actuated as per the set value of pressure sensor. Pressure is
also continuous varying parameter so the pressure sensor output is connected to analog
switch operated on voltage output. The set point is calculated as per the capacity of
container, force required to rotate the turbine. The voltage switch is connected to a memory
coil which is turned on when the pressure reached the set value. The memory switch directly
turns on the valve. A protection switch is designed as stated above for heater for emergency
exit of steam. Combining all above logic the whole ladder diagram for boiler automation can
be done.
According to the above steps stated with flow charts and full description we will design the
program for industrial boiler automation as follows.

4.3Assignment of input/output and ladder diagram development

4.3.1 Level and ph sensor controller
We select the inputs and outputs for level and PH sensor of the boiler and we put their
assignment symbols in the table below as shown.
Table 4.3.1 input/output assignment of level and PH sensor

No. Description/comment
Symbol
Inputs /Outputs
1 I0.0 Low level sensor
2 I0.1 High level sensor
3 I0.1 Used to deactivate motor pump
4 I0.2 PH sensor
5 Q0.0 Energizer coil
6 Q0.0 Auxiliary coil
7 Q0.1 Motor on
8 Q0.2 Tanker full
9 Q0.3 Motor off
10 Q0.4 Normally operated coil
11 Q0.5 Base valve
12 Q0.6 Acid valve
13 Q0.7 System runing
And we develop the ladder diagram as shown in the appendix

4.3.2 Fire detector sensor controller
We select the inputs and outputs of fire detector sensor of the boiler and we put their
Table 4.3.2 input/output assignment of fire detector sensor
symbols Description/comment
Inputs /Outputs
3 I0.1 For motor deactivation
4 I0.2 Fire sensor
5 T56 Timer coil
6 T56 Contact point timer
7 T60 Timer coil
8 T60 Contact point timer
9 Q0.0 Coil energizer for motor
10 Q0.0 Auxiliary contact
11 Q0.0 Contact coil for motor pump
12 Q0.1 Motor pump ON
13 Q0.2 Motor OFF
16 Q0.3 Contact coil for buzzer
17 Q0.4 Buzzer
18 Q0.4 Contact coil for timer T60
19 Q0.5 Sprinkler motor ON
20 Q0.6 Sprinkler motor OFF

4.3.3 Temperature sensor controller
We select the inputs and outputs of temperature sensor of the boiler and we put their
Table 4.3.3 input/output assignment of temperature sensor
Inputs /Outputs
1 I0.0 temperature sensor
2 Q0.0 Coil for heater activation
3 Q0.1 Timer energizer contact
4 Q0.2 Energizer contact for heater disabled
And we develop the ladder diagram as shown appendix
4.3.4 Oxygen and furnace oil sensor controller
We select the inputs and outputs of oxygen and furnace oil level sensor of the boiler and we
put their assignment symbols in the table below as shown.
Table 4.3.4 input/output oxygen and furnace oil sensor
Inputs /Outputs
1 I0.0 Oxygen sensor

4 T49 Timer coil
5 T49 Timer contact
6 T50 Timer coil

7 T50 Timer contact

10 Q0.0 Energizer for oxygen sacker motor
11 Q0.1 Oxygen sacker motor
12 Q0.1 Energizer coil for T49
15 Q0.2 Energizer coil for furnace oil pump
16 Q0.3 furnace oil pump
17 Q0.3 Energizer coil for T50
18 Q0.3 Heater energizer contact
19 Q0.4 Heater
4.3.5 Pressure sensor controller
We select the inputs and outputs of pressure sensor of the boiler and we put their assignment
symbols in the table below as shown.
Table 2 I/O assignment of pressure sensor
Inputs /Outputs
1 I0.0 Pressure sensor
2 Q0.0 Valve running indicator less 10mvar
3 Q0.1 Valve running indicator 0mvar
4 Q0.2 Valve running

4.3.6 Flow sensor controller

We select the inputs and outputs of flow sensor of the boiler and we put their assignment
symbols in the table below as shown.
Table4. 3.6 I/O flow Sensor assignment
Inputs /Outputs

3 I0.2 Flow sensor
4 I0.3 Temperature sensor
6 Q0.0 energizer coil
8 Q0.1 motor pump on
9 Q0.2 Tanker full
10 Q0.3 Motor pump off
11 Q0.4 Heater run indicator
12 Q0.5 Heater run indicator
13 Q0.6 Heater run
14 Q0.7 Energizer coil for a valve
15 Q1.0 Energizer coil for a valve
16 Q1.1 Valve

4.4 Over all boiler automation I/O assignment

Table 4.4 over all input/output assignment
N0 symbols Description/comment
Inputs
/Outputs
3 I0.1 Motor deactivation
4 I0.2 PH sensor
5 I0.3 Temperature sensor
9 I0.7 Smoke detector or fire sensor
12 Q0.0 Auxiliary coil
13 Q0.1 Motor on
14 Q0.2 Tanker full
15 Q0.3 Motor off
16 Q0.4 Normally operated indicator coil
17 Q0.5 Base valve
18 Q0.6 Acid valve
19 Q0.7 Normally operating system
20 Q1.0 Heater energizer coil
21 Q1.1 Heater energizer coil
22 Q1.2 Heater run
23 Q1.3 Valve energizer coil
24 Q1.4 Valve energizer coil
25 Q1.5 Valve run
27 Q1.7 Motor run
28 Q2.0 Tanker full
29 Q2.1 Motor off
31 Q2.3 Alarm
32 Q2.4 Sprinkler motor on
33 Q2.5 Sprinkler motor off

And we develop the ladder diagram as shown in the appendix for the above table.
4.5 Result and discussion

After we finish the software configuration of our project the final work what we are doing is
to simulate the ladder diagram circuits using step 7 simulator. After we simulate these
circuits we got what we are expected i.e. to automatically control the scopes determined
above. The conditions and their results are as follows:
1. Flow sensor. first the level sensor (i0.0) checks weather the tank level is low or high
and if the tank is at low level is the coil energizer (Q0.0) energizes the motor pump(Q0.1)
otherwise the motor pump is turn off. Next to level sensor the PH value of the water is
measured and also the temperature of the tank is checked with the temperature sensor (I0.2),
density sensor (I0.4), pressure sensor (I0.3), and finally flow sensor (I0.5) simultaneously as
shown ladder diagram in appendix B
2. Oxygen and oil furnace sensor
First the presence of enough oxygen in the firing tank is checked with the oxygen sensor
(I0.0) and if there is no oxygen, the fun motor starts to sack oxygen from the environment,
next the level sensor (I0.1) checks weather the oil tank level is low or high and if the tank is
at low the oil pump motor (Q0.3) stars to run until reaches high level and finally the heater
(Q0.4) is on since the oil, oxygen and the electrodes are ready. The timers are simply used as
for continuous operation of our system, that means no effects for on/off our system, the
system is on or off by the timers as we shown in the ladder diagram in the appendix
3. Fire sensor
Once again the level of sprinkler tank is checked by the level sensor (I0.0) weather water is
at low level or at high level and if it is at high, next weather fire is there in the boiler room or
not is cheeked by the fire sensor (I0.1), if there is fire, the sprinkler motor (Q0.5) is on to
spray water to the surrounding until the fire is disappear. Timers are used simply to
operating our system continuously. No effect to turn on/off for our system.
4. Pressure sensor
First the pressure of the boiler, inlet valve and out let valve is sensed by the sensors i0.0,
i0.1, i0.2 respectively and if the pressure is out of the pre set value the alarm(Q0.2) is turn
on and the valve(Q0.10 is closed. The timer is used to indicate continues operation.

5. Temperature sensor
The temperature sensor (I0.0) checks weather the temperature is the pre set value and if it is
so the heater is on otherwise the heater (Q0.1) is off. The timer is used to indicate continues
operation.
6. PH and level sensor
As usual also the level sensor is checked by the level sensor (I0.0) and is it is out of the pre
set value pump motor (Q0.0) is off and proceed to check the acidity or base city of the water
in the tank using the acid sensor (I0.2) or base sensor (I0.3), if it is acidic the base valve
(Q0.) is open and the acid valve (Q0.) is closed and vice versa. The timer is used to indicate
continues operation.

CHAPTER FIVE
5. Conclusion and Recommendation
5.1 Conclusion
The most important aspect of any power plant is the boiler control. Several techniques can
be implemented to control the boiler in power plant. The method that has to be used relies
on varied objectives like superior quality, increased efficiency, high profit and other such
points depending upon the purpose of the company that implies it. With the prime objective
of catering to these necessities and the needs of the industrial sector, significance has been
given here to automation.
This paper presented here has kept in mind, the ceaseless changes that are relentlessly taking
place in the contemporary scenario of the industrial segment. Emphasis has been given to
the automation process that is now rapidly taking its place in all the power plants across the
globe. The Paper has furnished itself to study the integral parts of the entire process
involved, their implementation and the problems that may show up have also been given
their due importance. The future work deals with the purification of water to the boiler and
the air circulation for the boiler to burn the fuel using same automation technique
5.2 Recommendation
In this project automatic PLC based controlled solution for industrial boiler automation has
been introduced. This is dealing only to 7 specific systems to control automatically using
PLC but this is may not be enough to control the entire all the industrial boiler components
and to make the industries profitable and to have system components good span life.
Therefore to operate our industrial boiler automatically and to control all component of
industrial boiler our future work is to control all the appliances of the boiler, by using
appropriate analog and digital sensors, but in our case only digital sensors are used due to
time and availability of software limitation. The
In addition to this what we want to recommend is that, in order to do a project the material
required to do the task must be fulfilled. The main problem what we are faced in process of
working our project is the shortage of the necessary materials (hard ware components).

Reference
[1] Albert Ting-pat so. Intelligent Automation System.
[2] Automation technology with Siemens PLC ABB 2008
[3] Google search
[4] Home automationgeek.com/top-3-books/
[5] L.A.Bryan and E. A. Bryan Programmable controller Theory and implementation
[6] JoonHeo.A Security Mechanism for Automation Control in PLC-based
Networks.
[7] Jon S. Wilson - Google Books Sensor Technology Handbook
[8] M Gauger home automation applications that integrate wireless sensor net-
works.
[9] M .varchola. Zigbee based home automation wireless sensor network. 2007.
[10] Prof. Hesham Khairy automation Technology
[11] "Programmable Logic Controllers PLCs." © 2001 High Tech Services HTS,
Cary,
[12] Raleigh, RTP, North Carolina, NC. http://www.htservices.com/Tools/PLC/..
[13] R.K. and Malik. Automation and security.
[14]"Welcome to PLC open." © 1993-2001 PLC open. http://www.plcopen.org/
[15] www.automation.siemens.com/mcms/.../References_book_2012.pdf

Appendix
A) Field devices
1. Ph probe
Table 4 Ph probe Specification
Specification
Reference Double, Ag/Ag cl
Junction Ceramic, single
Connector BNC
Electrolyte Kcl 3.5M
Max pressure 0.1 bar
Tip shape Spherical (dia:7.5mm)
Body material PEI(polyether-Imide)
Cable Coaxial,1 m(3.3’)
Recommended use Field application
2. valve
Table 5 solenoid valve Specification
Specification
Voltage 220VAC
Orifice 16 mm
Temperature -5o c to 80oc
Pipe size 0.5 in
Operating pressure 0 kg/cm2 to 10 kg/cm2

3. Pump motor
Table 6 pump motor specification
Specification
Voltage 220 VAC
Frequency 50 HZ
Ampere 2.6 A
Pumping capacity 40 L/min
power 0.5HP
B) Material required
Table 7 Material required
Material Type Qu Estimated

ant cost specifications
ity (optional)
Pump motor Ac 3 Voltage supply 220 VAC at a frequency of 50Hz
0
Boiler Furnace 1 US $5,000 – At a temperature 0f 0-200 c
Oil 30,000 / Set Pressure 0-10mvar
Boiler PH 0-14
Temperature High 1 $111.38 • 0 to 2000c

sensor temp • Sensor Cost: low
Pt100(- • 2, 20, 200 mA and 5A DC current ranges.
600cto • Isolated 4-20 mA or 0-10V isolated transmitter
5000c outputs, selectable.
• Output update rate: to 60/sec.
• Powered by AC or DC.
Pressure 3 Excitation: 24 to 32 Vdc; Operating Temp Range: -46
sensor to 121°C
Output: 0 to 5 Vdc
Solenoid 5 220VAC supply
valves -5o c to 80oc
Level sensor WA100 4 $139/
Liquid UNIT Outputs: 4-20 mA or 0.5 to 2.5 VDC across 125 ohms
Level Supply Voltage: 8 to 36 VDC
Float Current Draw: Same as sensor output
Switch

PH sensor PH 1 $20 • pH Reading: 0 to 14

probe
• mV Reading: -1250mV to 1250mV
ph107
• Solution Temperature: 0 to 100C
• Ambient temperature 40-700c
Smoke • Operating Voltage: 32VAC to 32Vdc

detector • Switching Current: 5 to 200mA
• Contact Resistance: <1 ohm
• Actuating Temp:(preset) 60 to 240°C
Flow sensor FP311 $962 -20 to +150°C
Voltage supply 3v
Buzzer King £1.82
State (euro) Supply voltage max 20
Buzzer Current rating 1ma
KPE- Tones continues
200 Sound level 73dB
Timer On
delay,
off delay
pushbuttons
relays industria
l
PLC software S7-200
PLC module semen’s 1

C) Ladder diagram
1 Flow sensor ladder diagram

Figure 4.4.1 Flow sensor simulation ladder diagram
2 Oxygen and oil furnace sensor
Figure 4.4.2 Oxygen and furnace oil sensor simulation logic ladder diagram

3 Fire sensors
Figure 4.4.3 fire detector sensor simulation logic ladder diagram

4 pressure sensor
Figure 4.4.4 pressure sensor simulation ladder diagram
5 temperature sensor
Figure 4.4.5 temperature sensor simulation ladder diagram

6 PH and level sensor

Figure 4.4.6 PH and level sensor simulation ladder diagram

Over all ladder logic diagram for industrial boiler automation using S-7 software




PLC Based Boiler Automation

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PLC Based Boiler Automation

Uploaded by

Copyright:

Available Formats

Plc based industrial boiler automation

ETHIOPIAN INSTITUTE OF TECHNOLOGY

PLC BASED INDUSTRIAL BOILER AUTOMATION

FINAL GRADUATING THESIS

IN PARTIAL FULFILLMENT FOR T

ELECTRICAL AND COMPUTER ENGINEERING

UNDER THE SREAM OF INDUSTRIAL CONTROL AND INSTRUMENTAION

MEKELLE ETHIOPIA JUNE 2013

Final year thesis, electrical and computer engineering 1

ETHIOPIAN INSTITUTE OF TECHNOLOGY

Assistant Professor Sisay Teklay

Industrial control chair: Assistant professo

Final year thesis, electrical and computer engineering i

Final year thesis, electrical and computer engineering ii

3.1.3 Sensors ........................................................................................................................................... 29

Final year thesis, electrical and computer engineering iii

Final year thesis, electrical and computer engineering i

Final year thesis, electrical and computer engineering ii

Ethiopian institute of technology Mekelle, Mekelle University

Assistant professor Sisay Teklay

Final year thesis, electrical and computer engineering iii

MAP Manufacturing automation protocol

PROM Programmable Read-Only Memory

TTL Transistor-transistor logic

Final year thesis, electrical and computer engineering iv

Above all, we would like to thank the almighty of GOD!!!

Final year thesis, electrical and computer engineering v

Final year thesis, electrical and computer engineering vi

Final year thesis, electrical and computer engineering 1

Final year thesis, electrical and computer engineering 2

Final year thesis, electrical and computer engineering 3

1.2 Objective of the thesis

• To reduce overall expenditure in terms of wages, wastage of material due to

• To increase plant production efficiency

• Controlling boiler before damaging, controlling boiler from hazards

1.3 Significance of the project

Final year thesis, electrical and computer engineering 4

1.4 Scope of the project

Final year thesis, electrical and computer engineering 5

Figure 1.5 over all block diagram of industrial boiler automation

Final year thesis, electrical and computer engineering 6

1.6 overview of the thesis

Figure 1.6a overview of the thesis

Final year thesis, electrical and computer engineering 7

1.7 industrial boiler process block diagram

Final year thesis, electrical and computer engineering 8

Figure 1.6b industrial boiler process block diagram

Final year thesis, electrical and computer engineering 9

1.7 Statement of the problem

Final year thesis, electrical and computer engineering 10

Final year thesis, electrical and computer engineering 11

Final year thesis, electrical and computer engineering 12

• Cost effective for controlling complex systems.

Final year thesis, electrical and computer engineering 13

2.3 Plc hardware

Final year thesis, electrical and computer engineering 14

Figure 2.3 plc hardware components and power flow direction

Final year thesis, electrical and computer engineering 15

2.3.3 Input modules and output modules:-

Final year thesis, electrical and computer engineering 16

2.3.4 Programming Terminal:-

2.3.5 Signal modules

2.4 Programming device:

Final year thesis, electrical and computer engineering 17