7/15/23, 11:53 PM A Guide to PLC and SCADA Automation in Steam Boilers - Boilers and Steam Boiler Manufacturer In Maharashtra,

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A Guide to PLC and SCADA Automation in Steam Boilers

A Guide to PLC and SCADA

Automation in Steam Boilers
BY RAKHOH /  THURSDAY, 10 FEBRUARY 2022 /  PUBLISHED IN BOILER

Steam Boilers are one of the most important equipment in any power plant and process industry that require
constant monitoring and inspection at frequent intervals. In a steam boiler, various sections are controlled at the
same time with primary sections, such as the boiler drum, a boiling section producing high-temperature water for
steam generation. Excessive water level leads to improper steam generation. Steam & Drum Level is critical and
difficult to measure and maintain to automate the system and reduce human errors. Precise control of the water
level in the drum is an important factor that is performed by developing a PLC and SCADA system. It helps to reduce
the manual operation and provide enhanced control and monitoring of the plant and process operations through a
SCADA system,  a centralized system for supervising the process by preparing the required data respective to process
changes.

Programmable Logic Controller (PLC):

Programmable Logic Controller (PLC) is a digital computer for automation that can re-program the logic as per the
users’ requirements in industries. PLC is also used for the internal storage of instruction for the function
implementation such as logic, sequencing, timing, counting, and arithmetic to control through digital or analog input/
output modules.

Working of Programmable Logic Controller (PLC):

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At the start of each operational cycle, the CPU brings in all the field input signals from the input signals from the
module to store them into internal memory as a process of the input signal. This internal memory of the CPU is
known as the process input image (PII).

The user program is available in the CPU program memory. The CPU takes the status of input from PII and processes
it in the user program, and its result is stored in the internal memory of the CPU. This internal memory is called
process output image. At the end of the program run, the CPU transfers the signal states in the process image output
to the output module and resultantly, to the field control.

Input-Output in PLC
Input Layout:
Feed Pump
RTD Transmitter
Level Switch
Pressure Transmitter
Output Layout:
Solenoid Valve for the water inlet
Solenoid Valve for Steam Outlet
Heater

Supervisory Control and Data Acquisition (SCADA):

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As the name suggests, SCADA stands for Supervisory Control and Data Acquisition that helps with the supervisory
level as it is not a complete control system. SCADA is used for monitoring and controlling plants or equipment. The
control may be automatic or managed by operator commands. The data acquisition is completed by the PLC’s
scanning the field inputs connected to the PLC that is usually at a fast rate. The central host scans the PTU’s at a slow
rate and the data is processed to detect alarm conditions. If an alarm is present, it is displayed on special alarm lists.

PLC and SCADA in Industries:

PLC and SCADA are used to develop and implement boiler automation. Various sensors measure the temperature,
pressure, and water level. The parameters are assessed through SCADA, and the operation is controlled by using
PLC. The entire arrangement shuts down if the temperature and pressure reach a predetermined value and the
automatic check valve opens to discharge the steam and pressure. An emergency alert is activated, and automatic
check valves are opened to avoid any hazardous failure. Boiler control is a crucial part of any process plant. 

The steam boiler in a process plant or power generation project is controlled through a variety of methods. The
method to be used is determined by several objectives such as rising profit, increased efficiency, superior quality, and
other factors that are dependent on the industry. Boiler automation has become vital for meeting the primary goal of
providing easy operation to these facilities and the needs of the industries. The changes that are consistently taking
place in the industrial sector are partially the result of boiler automation. The automation process, which is gradually
assuming its position in all process plants throughout the world, has been given priority. It has prepared itself to
examine the critical components of the entire process operation, along with their implementation and any difficulties
that may arise.

Conclusion:

Rakhoh Boilers are renowned for their efficient and reliable steam boilers, waste heat recovery boilers, thermic fluid
heaters, and boiler accessories since their inception in 1983. We also provide excellent boiler services like energy
audit, steam trap assessment, boiler automation, annual boiler maintenance, fuel conversion, etc., to enhance the
efficiency and productivity of steam boilers.

Learn more about our products and services at www.rakhoh.com

ABOUT RAKHOH

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