„Futurizm 14‟, (14th & 15th March 2014), „Pune District Education Association‟s College of Engg.
Manjari
(BK)‟, „Pune 412307‟,Chief Editor:„Dr.K.R.Harane‟,Editor: „Prof D.O.Patil‟, „Prof R.M.Sahu‟.
International Journal of Innovative Technology & Adaptive Management (IJITAM)
ISSN: 2347-3622, Volume-1, Issue-9 , June 2014
`
PROCESS AUTOMATION IN BOILER
Sunil Pasalkar
Department of Electronics Engineering P.D.E.A’S COEM, Pune, India
([email protected])
Abstract- Plant operators have to physically monitor production. Water can exist in the form of solid, liquid and
performance values and the quality of outputs to determine gas as ice, water and steam respectively. Steam is produced by
the best settings on which to run the production equipment. evaporation of water, which is a relatively cheap and plentiful
Maintenance is carried out at set intervals. This generally commodity in most parts of the world. Its temperature can be
results in operational inefficiency and unsafe operating adjusted very accurately by the control of its pressure, using
conditions. A process automation is used to automatically simple valves; it carries relatively large amounts of energy in
control a process such as food, chemical, oil refineries, a small mass, and when it is encouraged to condensate back to
paper and pulp Industries while considering energy water, high rates of energy flow into the material being heated
efficiency. This paper focus on process automation used in are obtained, so that the heat using plant does not have to be
boiler. Steam is most economical, flexible and versatile unduly large[8]. The chemical energy, which is contained in
tool for industry wherever heating is required. It uses a coal, gas or other boiler fuel, is converted into heat energy
network to interconnect sensors, controllers, operator when the fuel is burned. That heat energy is transmitted
terminals and actuators. The information is stored and through the wall of the boiler furnace to the water. The
analyzed on a computer and the entire plant and each piece temperature of the water is raised by this addition of heat
of production equipment can be monitored on a large screen energy until saturation point is reached – it boils. The heat
in a control room. energy which has been added and which has had the effect of
raising the temperature of the water is known as the liquid
Keywords- boiler , instruments, PLC, process automation,
enthalpy. At that point of boiling, the water is termed
SCADA
Saturated Water. The water in our boiler is now at saturation
I. INTRODUCTION (boiling) point at 100 °C. Heat transfer is still taking place
Process automation involves using computer technology and between the furnace walls and the water. The additional
software engineering to help power plants and factories in enthalpy produced by this heat transfer does not increase the
industries as diverse as paper, mining and cement operate temperature of the water. It evaporates the water, which
more efficiently and safely. Process automation simplifies this changes its state into steam. The enthalpy that produces this
with the help of sensors at thousands of spots around the plant change of state without change of temperature is known as the
that collect data on temperatures, pressures, flows and so on. enthalpy of evaporation. The job of a boiler is to supply good
The information is stored and analyzed on a computer and the quality dry steam at the correct pressure at the right time.
entire plant and each piece of production equipment can be II. BOILER
monitored on a large screen in a control room. Plant operating
settings are then automatically adjusted to achieve the Boiler is a closed vessel in which the heat produced by the
optimum production. Plant operators can manually override combustion of fuel is transferred to water for its conversion
into steam at the desired temperature and pressure. Boiler
the process automation systems when necessary optimum
www.ijitam.org
„Futurizm 14‟, (14th & 15th March 2014), „Pune District Education Association‟s College of Engg.Manjari
(BK)‟, „Pune 412307‟,Chief Editor:„Dr.K.R.Harane‟,Editor: „Prof D.O.Patil‟, „Prof R.M.Sahu‟.
International Journal of Innovative Technology & Adaptive Management (IJITAM)
ISSN: 2347-3622, Volume-1, Issue-9 , June 2014
`
accessories are Feed pump ,Injector, Economizer , Air pre- III. PROCESS AUTOMATION
heater, Super heater , Steam separator.
Various Instruments, sensors are used like RTD ,flow
Boiler efficiency = (Eout – Efw)/Efuel (1) transmitter ,Self Acting Temperature Control Valve ,Compact
on-off Valve, PID base Temperature Control System
Eout : amount of energy in the steam or hot water ,temperature gauge, control valve, level transmitter etc.
Efw : amount of energy in feedwater
Efuel : amount of energy in fuel
A boiler is a closed vessel in which water or other fluid is
heated. The fluid does not necessarily boil. The heated or Fig.3,RTD
vaporized fluid exits the boiler for use in various processes or
heating applications including central heating, boiler-based
power generation, cooking, and sanitation. The basic
components of a water-tube steam boiler are the furnace,
where air and fuel are combined and burned to produce
combustion gases, and a water-tube system, the contents of
which are heated by the combustion process. The tubes are Fig.4,flow meter
connected to the steam drum, where liquid and vapor are
separated and the generated water vapor withdrawn. If
superheated steam is to be generated, the steam from the drum
is passed through the superheater tubes, which are exposed to
the combustion gases. A 1% loss in efficiency on a 100,000
lb/hr (45,360 kg/hr) boiler will increase its yearly operating
cost by about $20,000. A 1% efficiency loss can result from a Fig.5.temperature gauge
2% increase in excess oxygen or from about a 50°F (28°C)
increase in exit flue-gas temperature[7].
Fig.6.valve
Fig.1.boiler
A.CONTROL LOOP TYPES.
A single control loop includes a controlled variable sensor,
controlled variable transmitter, controller, automatic-manual
control station, and final control element. Control loops used
for boilers may be of the pressure, temperature, liquid level
type, or flow type [9]
PRESSURE
Fig.2.Water tube boiler
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„Futurizm 14‟, (14th & 15th March 2014), „Pune District Education Association‟s College of Engg.Manjari
(BK)‟, „Pune 412307‟,Chief Editor:„Dr.K.R.Harane‟,Editor: „Prof D.O.Patil‟, „Prof R.M.Sahu‟.
International Journal of Innovative Technology & Adaptive Management (IJITAM)
ISSN: 2347-3622, Volume-1, Issue-9 , June 2014
`
Pressure control loops may be used for the control of boiler and flow indicator controller. If there is any error
pressure or fuel oil pressure. For the control of boiler pressure, corresponding to desired set point, the signal from controller
the final control element regulates fuel flow to the boiler in is given to the converter which will open or close the valve
response to boiler drum steam pressure. For the control of fuel and the water will be drained out or filled according to
oil pressure, the final control element is usually a pressure required steam.
reducing control valve that regulates in response to
downstream pressure. Drum Level Control Systems are used extensively throughout
the process industries and the Utilities to control the level of
TEMPERATURE boiling water contained in boiler drums on process plant and
help provide a constant supply of steam.
Temperature control loops may be used for the control of
steam temperature from boilers or fuel oil temperature from If the level is too high, flooding of steam purification
fuel oil heaters equipment can occur.
LEVEL If the level is too low, reduction in efficiency of the treatment
and recirculation function.
Liquid level control loops may be used for the control of Pressure can also build to dangerous levels.
boiler drum water level. FLOW A drum level control system tightly controls the level
whatever the disturbances, level change, increase/decrease of
steam demand, feedwater flow variations.
Flow control loops may be used for the control of fuel flow
into the boiler burners, burner draft airflow, feed water into a
boiler, or steam flow out of a boiler It Provide controls to always maintain the boiler drum level
within the boiler manufacturer's specifications under all
operating conditions. Three types of control systems used in
ALARMS
boiler plants are single element, two element and three
element.
Furnish alarms to announce the approach of unsafe conditions.
Provide shutdowns to shut the equipment down under unsafe
A single element control system utilizes just a level
conditions
transmitter to maintain control of the boiler drum water level.
Use a single element control system only for boilers operating
BOILER DRUM LEVEL at steady loads.
A two element control system utilizes a level transmitter and
the amount of steam flow from the boiler to maintain control
of the boiler drum water level. A two element control system
provides some compensation for variable loads. It does not
adequately correct for the expansion of water within a boiler
due to the decreased boiler pressure that occurs when a large
amount of steam is required, or for the contraction of heated
Fig.7.boiler control water in a boiler due to the addition of cold feedwater.
The block diagram of boiler control is shown in above figure
the output from the boiler i.e, the steam outputs and the level
of water is given to transmitters. The output of transmitter is
given to the controller which act as level indicator controller
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„Futurizm 14‟, (14th & 15th March 2014), „Pune District Education Association‟s College of Engg.Manjari
(BK)‟, „Pune 412307‟,Chief Editor:„Dr.K.R.Harane‟,Editor: „Prof D.O.Patil‟, „Prof R.M.Sahu‟.
International Journal of Innovative Technology & Adaptive Management (IJITAM)
ISSN: 2347-3622, Volume-1, Issue-9 , June 2014
`
call for frequent manual adjustment if the heat requirements
of the equipment in question are liable
to fluctuate significantly. More accurate control can be
obtained by the installation of a pressure reducing valve but
the need for manual adjustment still remains. The ideal
answer is to fit one of the Automatic Self Actuating
Temperature Control System
Fig 8.two element control
A three element control system utilizes a level transmitter, the
amount of steam flow from the boiler and the amount of water
into the boiler to maintain control of the boiler drum water
level. The steam flow from the boiler is usually compensated
for pressure and temperature. A three element control system
corrects the problems associated with a two element control
system and provides the best method of compensating for
variable loads[9].
Fig .9.on-off temperature control system
Metering control system
In this system control is regulated in accordance with the
measured fuel and air flows. This maintains combustion
efficiency over a wide load ranges & over long period of time.
Feedwater control is the regulation of water to the boiler
drum. It provide a mass accounting system for steam leading
and feedwater entering the boiler.
Combustion efficiency
It can be determined if proper information is available on fuel
analysis, fuel gas analysis, combustion air temperature and
stack temperature using manometer.
Fig .10.PID temperature control system
B. Temperature control Mathematically proportional+integral+derivative mode
controller can be expressed as,
Temperature control can be achieved by manually throttling
P(t) = Kp e(t) + KpKi e(t)dt + )KpKd de(t)/dt + p(0) (2)
the steam valve and manipulating steam flow, in the same way
that a gas tap is used to regulate the supply of heat on a Where p(0) = initial value of the output.
domestic cooker. Unfortunately, such anarrangement may C.PLC
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„Futurizm 14‟, (14th & 15th March 2014), „Pune District Education Association‟s College of Engg.Manjari
(BK)‟, „Pune 412307‟,Chief Editor:„Dr.K.R.Harane‟,Editor: „Prof D.O.Patil‟, „Prof R.M.Sahu‟.
International Journal of Innovative Technology & Adaptive Management (IJITAM)
ISSN: 2347-3622, Volume-1, Issue-9 , June 2014
`
To overcome the disadvantages of relay logic controller, a D.SCADA
programmable logic controller was developed
.A Programmable Logic
supervisory control and data acquisition is a type of industrial
Controller, PLC or Programmable Controller is a digital
control system(ICS). Industrial control systems are computer-
computer used for automation of electromechanical
controlled systems that monitor and control industrial
processes, such as control of machinery on
processes that exist in the physical world.
factory assembly lines, amusement rides, or light fixtures.
PLC consist of processor, input modules ,output modules,
programming software . Scan time tells how much time is E. HMI
required for plc to complete cycle of i/o scan and
execution. Typical scan time of PLC is 20 ms. A human–machine interface or HMI is the apparatus or device
Programming unit is an interface between the user and the which presents processed data to a human operator, and
PLC. Ladder diagram is a special schematic through this, the human operator monitors and interacts with
representation of the hardware elements and its the process. The HMI is a client that requests data from a data
connection, used to make the combination of hardware acquisition server.
and description of sequence of events clear is called
ladder diagram. In ladder diagram address number is PLC , SCADA interfacing required communication cable,
specified to each device. driver ,server etc.
F. The EffiMax 2000 package
It provides a complete monitoring and data acquisition
solution for boiler performance. This sophisticated yet simple
to use analyzer operates on-line continuously, monitoring your
boiler efficiency every instant of its operation.
EffiMax calculates the efficiency of the boiler based on
indirect efficiency computation and computes individually the
total amount of losses like stack loss, enthalpy loss, radiation
loss and blow down loss in your boiler. Using the data
generated on the system losses, on-line suggestions can then
be used to fine tune the system to generate more steam with a
lower quantity of fuel.
The Model 353 Process Automation Controller is a stand-
alone, microprocessor-based industrial controller designed for
a broad range of process applications. It can serve as a simple
single-loop controller or as a multi-loop controller with
complete control and logic functions for a small unit batch or
fig.11.PLC block diagram continuous process. The Model 353‟s field bus and
networking options enable it to function as an integral element
in a plant system. Loops are configured for control, sequence,
or logic as needed within the Model 353. Each configured
loop can have a virtual operator display that is viewed locally
using the LOOP button on the faceplate and is mapped to
network communication for a plant operator station. Alarm
management is handled using the L (Loop) & S (Station)
indicator lights along with the priority assignments and
flashing options of each alarm.
The MICROCON DCS system is modular and expandable and
Fig.12. Allen-Bradley PLC
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„Futurizm 14‟, (14th & 15th March 2014), „Pune District Education Association‟s College of Engg.Manjari
(BK)‟, „Pune 412307‟,Chief Editor:„Dr.K.R.Harane‟,Editor: „Prof D.O.Patil‟, „Prof R.M.Sahu‟.
International Journal of Innovative Technology & Adaptive Management (IJITAM)
ISSN: 2347-3622, Volume-1, Issue-9 , June 2014
`
provides unique solutions to handle both continuous and batch routine manual and clerical tasks, to improve worker safety, to
applications in the same hardware. Automation for different improve product quality, to reduce manufacturing lead time,
types of fuel fired boilers and turbines. Special techniques for to accomplish what cannot be done manually, to avoid the
combustion control. Sequence of event recording @ 1 ms time high cost of not automating.
stamping.
Also Advanced PLCs, DCS with remote IO Capability ,
V. CONCLUSION
TCP/IP communication upto 1Gbps, Mesh Topology for
reliable network,Graphical Drag and Drop facility for logic
configuration,Boiler Tube Leakage Detection Thus process automation plays an important role in boiler
System ,Furnace TV,Management Information System used in various fields.
interface with external world and office automation system
can be used in boiler automation. VI. FUTURE SCOPE
IV. ADVANTAGES
Make automation system more efficient and more user
To increase labor productivity, to reduce labor cost, to friendly.
mitigate the effects of labor shortages, To reduce or remove
Fig. 13.boiler SCADA SCREEN
[3]. Hillenbrand, Cary, Expert Three, Technical expert specializing in the
VII. ACKNOWLEDGMENT planning and design of SCADA based and Distributed control system.
[4]. Boyer, Stuart, A. SCADA: Supervisory Control and Data Acquisition,
Instrument Society of America, Research Triangle, NC. 1993.
I am grateful to Prof .R.M.SAHU, Prof. R.K. MOZE, Prof. [5]. Ezell, Barry, “Scenarios One and Two: Source to No 1 PS to No 1 Tank
S.M.BANKAR for their support and encouragements to No 2 PS to No 2 tank (High level) for a Master-Slave SCADA
System”, SCADA Consultants, SCADA Mail List,
[email protected] (August 1997).
REFERENCES .[6].MICHEL P GROVER :automation computer integraed system and
manufacturing system.
[7]. Process control & optimization, VOLUME II: B.G.liptak.
[1]. Ezell, Barry, “Supervisory Control and Data Acquisition Systems for [8].Forbes Marshall services &product.
Water Supply and Its Vulnerability to Cyber Risks” available on the internet [9].Introduction to Boiler Control Systems: J. Paul Guyer, P.E., R.A., Fellow
at: http://watt.seas.virginia.edu/~bce4k/home.html. ASCE, Fellow AEI.
[2]. Rockwell Automation SCADA System Selection guide Allen-Bradley,
Publication AG-2.1.
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