Barelwala Chintan Tulsiram Assistant Professor- Mechanical Engineering Gandhinagar Institute of Technology, Kalol Boiler Automation is one of it which demands determination of certain physical parameters & utilizing these parameters to make the boiler start- stop or function in any manner we want, but automatically. 18| DECEMBER 2012 AUTOMATION & CONTROL OF BOILER OPERATIONS THROUGH PROGRAMMABLE LOGIC CONTROLER Cure! engineering has evolved over time. PLC applications are extensively used in industries to control and facilitate repetitive processes such as manufacturing cell ‘management, fly-by-wire control, or nuclear plant systems. One of these applications is industrial automation which includes numerous automated processes. Boiler ‘Automation is one of it which demands determination of certain physical parameters & utilizing these parameters to make the boiler start-stop or function in any manner we want, butautomatically Control engineering has evolved over time. In the past humans were the main methods for controlling a system. More recently electricity has been used for control and early electrical control was based on relays. These relays allow power to be switched on and off without a mechanical switch. It is common to use relays to make simple logical control decisions. The development of low cost computer has brought the most recent revolution, the Programmable Logic Controller (PLC). The advent of the PLC began in the 1970s, and has become the most common choice for manufacturing controls. ‘Automation means delegation of Human Control to technical Equipment aimed to wardsachieving Advantages Higher productivity, superior quality of end product, efficient usage of raw materials and energy, improved safety in working condition, History of Control and Automation PLC ELECTRICAL CONTROL WITHLOGICGATES WITHLOGICGATES MANUAL CONTROLPROGRAMMABLE LOGIC CONTROLER Manual Control In this, the Control and Automation are done by Manual Operations. Drawbacks: * Human Errors subsequently affect quality of end product. + Hard Wired Logic Control + Inthis, Contractor and relays together with timers and counters were used in achieving desired level of automation. * Bulky and complex wiring, Involves lot of rework to implement changes in control logic, the work can be started only when the takes is fully defined and this, leads o longer projecttime. Electronics Control with Logic Gates In this, Contactor and Relays together with timers and counters were replaced with logic gates and electronic timersin the control circuit. Advantages + Reduced space requirements, energy saving, less maintenance and hence greater reliability Drawbacks ‘+ Implementation of changes in the control logic as well as reducing the project lead- time was not possible. Programmable Logic Controller PLC is a specialized computer used to control machines and process. It uses a programmable memory to store instructions and specific functions that include ON/OFF control, timing, counting, sequencing, arithmetic and data handling. In this, instead of achieving desired control and automation through physical wiring of control devices, it is achieving through program say software, ‘Advantages of a PLC Control System Mor Feit (rginl equipment manufacturers (OEMs) can provie sytem updates Jora process by my sending out new progam ei cana to crate and change «program inaRcben ove od rere a creat Endasers can modty the rogram int fa Figure 1: PLC application in Automation PLC applications are extensively used in industries to control and facilitate repetitive processes such as manufacturing cell management, fly-by-wire control, or nuclear plant systems. One of these applications is industrial automation which includes numerous automated processes. This again includes boiler automation which demands determination of certain physical parameters (viz. pressure, temperature, etc.) & utilizing these parameters to make the boiler start-stop or function in any manner we want, but automatically, without involvement of any human. Nowadays, every new industry before stepping into the production line, never gives up thinking about ways of automating its production process, so as to reduce it's overall ‘expenditure in terms of wages, wastage of material due to inaccurate manual work and to reduce the overall time taken for production, Thisis where the job of PLCs comes into picture. PLC System Power romana rc =e ss Peonerrgance Figure 2: PLC System There are many companies manufacturing PLC trainer kits. Companies like Siemens, Allen Bradley, ABB, LG, Mitsubishi, Omron, GE Fanuc are the leading global manufacturers of PLCs, each varying from the other in terms of CPU memory, number of digital and analog PLC Size Classification Allen-Bradley SLC-500 Family Handles up to 960 I/O points Allen-Bradley PLC-5 Family - Handles several thousand 0 points, Figure 3: PLC Size Classification DECEMBER 2012! 19inputs and so on. The main theme behind using a PLC is reduction of cost as well as complexity of incorporating huge number of electrical devices, easier error detection, ‘optimization of overall production time and above all automation Drawback of Conventional System Conventional equipment systems are prone to errors due to the involvement of humans in the data collection and processing using complicated mathematical expressions. Thus what we require is a system that collects raw data, processes it and presents it in values which can be verified and compared with the standard values. In the coding process of this implementation with micro- controller, it requires a fast and efficient processing which on the other part depends on the length and sub- routines of the coding process. Thus it provides a real challenge with systems involving, : Advantages of PLC Reduced Space, Energy saving, Modular Replacement, Easy trouble shooting, Error diagnostics. programmer, Economical, Greater life and reliability, The Compatibilities of PLC’S, Logic Control, PID control, Operator control, Signaling and listing, Coordination and communication. Applications The main advantage of using PLCs isthe drastic reduction in the requirement of electrical components in terms of umber of switches, relays, wiring, etc. the applications of this project are solely the applications of a boiler i.e., production of steam and using it for numerous processes. like rotating the generator fins and hence producing power for commercial or industrial purposes. How PLC Works ? Basics of a PLC function are continual scanning of a program. The scanning process involves three basic steps. ‘Step 1: Testing input status Firstthe PLC checks each of its input with intention to see which one has status on or of. In other words it checks whether a switch ora sensor etc,,is activated or not. The information that the processor thus obtains through this step is stored in memory in order to be used in the following steps. 20|DECEMBER 2012 PROGRAMMABLE LOGIC CONTROLS, Step 2: Programming execution Here a PLC executes a program instruction by instruction based on the program and based on the status ofthe input has obtained in the preceding step, and appropriate action is taken. The action might be activation of certain ‘outputs and the results can be put off and stored in ‘memory to be retrieved laterin the following steps. Step 3: Checking and Correction of output status Finally, a PLC checks up output signals and adjust it has needed. Changes are performed based on the input status that had been read during the first step and based on the result of the program execution in step two ~ following execution of step three PLC returns a beginning of the cycleand continually repeats these steps. Scanning time = Time for performing step 1+ Time for performing step 2+ Time for performing step 3. Ladder Logic Ladder logic is the main programming method used for PLCs. As ‘mentioned before, ladder logic has been developed to mimic relay logic. The decision to use the relay logic diagrams was a strategic one. By selecting ladder logic as the main programming method, the amount of retraining needed for engineers and trades people was greatly reduced. PLC Ladder Logic Program ‘oe 12 La rn r 1 Mapas pit % or + The format used is simitar to that of the hard-wired relay circuit Figure 4: PLC Ladder Logic Program Boiler Automation Through PLC Over the years the demand for high quality, greater efficiency and automated machines has increased in this globalised world. The initial phase of the paper focuses on passing the inputs to the boiler at a required temperature, so as to constantly maintain a particular temperature in the boiler. The Air preheater and Economizer helps in this process. Use of PLC focuses onlevel, pressure and flow control at the various stages of the boiler plant. Thus the temperature in the boiler is constantly monitored and brought to a constant temperature as required by the power plant. All the parameters and values can be filled up by the introduction of the automation technique into the power plants. The automation technique involving the automatic control of al the processes which includes the monitoring and inspection needs provides for a very efficient system. The automation process helps the ‘company having the power plant to reciuce the amount of errors that occur, reduction in the human resources, increased efficiency, and most importantly very cost effective. Figure 5: PLC installation in Boller PLC is responsible for collection of data from field sensors (within the boiler), evaluate them & generate appropriate output for the boiler to operate in a specific desired procedure. Initially, we divided our project into four sections viz., power supply section, water supply section, boiler (including sensors) section, process controlling section. Boiler Section: Boiling container, sensors (pressure, temperature & level sensors) & a heater assemble altogether to give riseto the boiler section. Controlling Section: This section includes the PLC which is responsible for data collection from field sensors, evaluation of collected data & generation of appropriate output overall system Water Supply Section: Water supply to the boiler is ensured by a water pump whose actuation & termination iscontrolled by the PLC. Figure 6: Drawing view of PLC installation in Boller Power Supply Section: This takes care of the power requirements, This mostly comprises of the circuits providing DC power for the field sensors and valves Golenoids) Figure 7 : PLC SCADA Sereen Result Model Critical Control Parameters in Boiler ‘A. Level Control ‘Steam Drum level, De-aerator level and hot well level. B. Pressure Control Force draft pressure, Induced draft pressure, Steam drum pressure, Deaerator pressure, Turbine inlet steam pressure, balanced draft pressure. 9 Flow Control Airflow, Steam flow, Waterflow i D. Temperature Control Deaerator temperature, Steam drum temperature, Underbed boiler temperature, Turbine inlet steam temperature, Flue gas temperature. The automation is further enhanced by constant ‘monitoring using SCADA ((Supervisory Control and Data Acquisition) screen which is connected to the PLC by means of communication cable. By means of tag values CONTINUE ON PAGE 33 DECEMBER 20121 21The disinfection and oxidizing property of Proforma for condenser performance chlorine is due to Fo aw a et ag Hypochlorous acid Hypochlorous acid i dissociates into hydrogen | 2 _tme and Hypochlorite (OCI) ions |B Noad mw 210 depending upon temperature | _Vacuurrback pressure: Mmofhg 89 and pH The disoition spent). i a Cl is not so effective os [2 Between) xc 49 HOCI. Hence effectiveness [8 Giinlettemp.(@) *c 36 of chlorine reduces at higher |[&_ Gwoutlettemp (t2) oe 45.75 pH. 9 Dpacrosscond. Kgem 475 Chlorine presents as Ocl- P= erubeehinelumsine/ Co fow ies ie a and HOCI is collectively Z termed as free residual Tube cleaning 13412 2 chlorine. Chlorination along Airingress 43 o with low molecular weight tat B polymer Keeps the system aes clean. d___Hotwell flooding 14-12, 3 1342 3 CN aed AUTOMATION & CONTROL OF BOILER OPERATIONS THROUGH PROGRAMMABLE LOGIC CONTROLER set to various variable in SCADA the entire process is controlled as required. At the automated power plant the boiler is controlled by Variable Frequency Drive (VED) to put in action the required processes to be carried out atthe boiler. Thus the entire cycle is carried out as a paper and at various stages each phase is detailed out. In order to automate a 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 intemal storage of instruction for the implementing function such as logic, sequencing, timing, counting and arithmetic to control through digital or analog input/ out put modules various types of machines processes. Systems, are used to monitor and control a plant or equipment in industries such as telecommunications, water and waste control, energy, oil and gas refining and transportation, 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 article presented here about 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 future work may deals | with the purification of water to the boiler and the air Circulation for the boiler to burn the fuel using same_| automation technique. 0 | DECEMBER 2012 | 33