Paste your esGUJARAT TECHNOLOGICAL UNIVERSITY
Chandkheda, Ahmadabad.
Affiliated
SARVAJANIK COLLEGE OF ENGINEERING & TECHNOLOGY
A REPORT ON
BOILER AUTOMATION USING PLC, SCADA AND HMI
B.E. IV, Semester – VIII
(Electrical Engineering)
Type of project: UDP (User Datagram Protocol)
Submitted by:
TEAM ID: 26199
Sr. No. Name of student Enrolment No.
1. NAUSHADALAM ANSARI 140420109004
2. BHAVIN ORNAWALA 140420109011
3. KAIVEN SHAH 140420109024
4. PARTH KAJIWALA 140420109025
5. TANVIRAHMED KAZI 140420109026
Prof. HEMIN D. MOTIWALA Prof. ( Dr.) SANDHYA RATHORE
( Internal Guide ) ( Head of the Department )
Academic year (2017-2018)
Table of content
Acknowledgement
Chapter: 1 Introduction………………………………………………………………………….. 4
1.1 Problem Summary and Introduction………………………………………… 4
1.2 Aim and Objectives of the Project…………………………………………… 4
1.3 Problem Specifications………………………………………………………..
1.4 Brief Literature Review and Prior Art Search (PAS) about the Project………
1.5 Plan of their work…………………………………………………………….
1.6 Materials / Tools required……………………………………………………. 7
Chapter: 2 Design: Analysis, Design methodology and implementation strategy………………
Chapter: 3 Implementation………………………………………………………………………
Chapter: 4 Summary of result……………………………………………………………………
4.1 Summary……………………………………………………………………..
4.2 Advantages and Disadvantages………………………………………………
4.3 Scope…………………………………………………………………………
References……………………………………………………………………………………….
Appendix…………………………………………………………………………………………
ACKNOWLEDGEMENT
The satisfaction and euphoria that accompany the successful completion of any task would be
Incomplete without mentioning the people whose constant guidance and encouragement made it possible. We take pleasure in presenting before you, our project, which is result of studied blend of both research and knowledge.
We express our greatest gratitude to our internal guide, Prof. HEMIN MOTIWALA department of EE, Our project guide, for his constant support and Guidance.
Finally, we express our gratitude to all other members who are involved either directly or indirectly for the completion of the project.
CERTIFICATE
Sarvajanik College of Engineering and Technology
Surat
This is to certify that report, submitted along with the project entitled “ BOILER AUTOMATION USING PLC, SCADA AND HMI ” has been carried out by
Name
Enrolment No.
NAUSHADALAM ANSARI
140420109004
BHAVIN ORNAWALA
140420109011
KAIVEN SHAH
140420109024
PARTH KAJIWALA
140420109025
TANVIRAHMED KAZI
140420109026
in fulfillment for the degree of Bachelor Of Engineering in Electrical Engineering Affiliated To Gujarat Technological University, Ahmedabad during the academic year 2017-18.
Prof. HEMIN D. MOTIWALA Prof. ( Dr.) SANDHYA RATHORE
Internal Guide Head of Department
CERTIFICATE
Sarvajanik College of Engineering and Technology
Surat
This is to certify that report, submitted along with the project entitled “ BOILER AUTOMATION USING PLC, SCADA AND HMI ” has been carried out by
Name
Enrollment No.
NAUSHADALAM ANSARI
140420109004
BHAVIN ORNAWALA
140420109011
KAIVEN SHAH
140420109024
PARTH KAJIWALA
140420109025
TANVIRAHMED KAZI
140420109026
in fulfillment for the degree of Bachelor Of Engineering in Electrical Engineering Affiliated To Gujarat Technological University, Ahmedabad during the academic year 2017-18.
External guide
Introduction
1.1 Problem Summery
Boiler is a very crucial part of any power plant. So to operate Boiler very effectively and safely it is necessary to make all the operations automatically. If one of the parameter of the boiler goes beyond the limits then there can be severe problem occur in the whole system and it may damage the boiler and other equipments. In India, Many Boilers are not still fully automated and rely on the human operation which is less reliable. Due to little error of human there can be a large problem in the plant so it should be avoided.
1.2 Aim and Objective of the project
Our main aim is to make the boiler system fully automated and thus make it more Reliable and Human errors free. By saying fully automated, we mean that according to load we can change the input of the fuel required and water level tank input and output and temperature of the boiler will be changed and make the whole system sustainable and safe. The whole process can be controlled by the PLC and can be operated with SCADA software and HMI. Whole process can be visualized on the SCADA system and thus changes can be made accordingly in the system. Alarms must be there to give emergency signals so that operator can take his actions as soon as possible.
1.3 Problem Specifications
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 microcontrollers.
• 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.
1.4 Brief Literature Review and Prior Art Search (PAS) about the Project
Boiler Automation Using PLC & SCADA-
Automation control system in operation development, improving management level and high efficiency process in boiler automation plant. In the boiler automation plant sensor need to be controlled and monitored temperature regularly. Thus it becomes tedious job to handle the plant manually. This project outlines the design and development of boiler automation system using PLC and sensors.
SCADA is a centralized system used to supervise a complete plant and basically consists of data accessing features and controlling processes remotely. It is used to monitor the boiler temperature, pressure and water level using different sensors and the corresponding output is given to the PLC which controls the boiler temperature, pressure and water level. If the temperature and pressure inside the boiler exceeds the predefined value then the entire system is shut down. In case of emergency different automated check valves are used to release pressure, steam and inform the concerned authority.
Boiler is one of the most important equipment in any power plants which require continuous monitoring and inspection at frequent intervals. There are possibilities of errors at measuring and various stages involved with human workers. So a reliable monitoring system is necessary to avoid catastrophic failure, which is achieved by Programmable Logic Controller & Supervisory Control and Data Acquisition system. This paper outlines the design and development of boiler automation system using PLC, SCADA and sensors.
SCADA is used to monitor the boiler temperature, pressure and water level using different sensors and the corresponding output is given to the PLC which controls the boiler temperature, pressure and water level. If the temperature and pressure inside the boiler exceeds the predefined value then the entire system is shut down.
PSAR gives the information about the how the flow of research of our project was there. In the very initial Stage we made our basic layout of project in which we have categorised the equipment used and their specifications. We have visited places to gather information about the equipment and their availability. Challenge you have faced was Synchronization between the equipments according to their output levels and specifications was a difficult challenge for us. Also it was very difficult to get the equipments available at the local stores. We needed the guidance of our mentor to help us out to find the synchronization between the equipments. After that we have talked to various technical persons from where to get the equipments cheaper. This report gathers the information about periodic progress of project. According to it we have filled 4 PPR.
1.5 Plan of their work
We have searched the research papers of boiler automation using PLC SCADA and HMI manuals.
First of all according to the application of our project, we have decided PLC (DELTA), with desirable amount of inputs and outputs.
According to which the supply form main terminal is divided through SMPS (SWITCH MODE POWER SUPPLY) .PLC needs 24 V DC, and other sensitive devices such as HMI, Temperature Sensor, relay cards, detectors.
Many research and coding problem also occurred at the time of working.
We have interfaced the HMI screen with PC and display the temperature measured thought it.
The plc screen contains 3 to 4 display which gives the information load variation, water level and alarm display.
We have coded the PLC program which works as it sensor the temperature and according the fan starts working ,and the temperature is maintain ,after the normal temperature is archived. The fan stops.
All the functions and devices are interfaced and the variation is obtained on display screen
HMI is also coding according to which it worked, as the temperature changes ,there changes are detected by sensors and display on the screen .
1.6 Material and tools required
HMI
INtouch SCADA Software
DELTA PLC
DTC 100 Temperature sensor
Relays
Solid State Relays
SMPS (Switch mode Power supply)
Thermocouple
MCB (Miniature circuit breaker)
RS-485 Communication cable
Fuses
Connectors
PLC
A programmable logic controller (PLC) or programmable controller is an industrial digital computer which has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, or robotic devices, or any activity that requires high reliability control and ease of programming and process fault diagnosis.
A PLC is an example of a "hard" real-time system since output results must be produced in response to input conditions within a limited time, otherwise unintended operation will result.
A visual programming language known as the Ladder Logic was created to program the PLC.
PLC Hardware:-
The hardware components of a PLC system are CPU, Memory, Input / Output, Power supply unit, and programming device. Below is a diagram of the system overview of PLC.
CPU – Keeps checking the PLC controller to avoid errors. They perform functions including logic operations, arithmetic operations, computer interface and many more.
Memory – Fixed data is used by the CPU. System (ROM) stores the data permanently for the operating system. RAM stores the information of the status of input and output devices, and the values of timers, counters and other internal devices.
I/O section – Input keeps a track on field devices which includes sensors, switches.
O/P Section – Output has a control over the other devices which includes motors, pumps, lights and solenoids. The I/O ports are based on Reduced Instruction Set Computer (RISC).
Power supply – Certain PLCs have an isolated power supply. But, most of the PLCs work at 220VAC or 24VDC.
Programming device – This device is used to feed the program into the memory of the processor. The program is first fed to the programming device and later it is transmitted to the PLC’s memory.
System Buses – Buses are the paths through which the digital signal flows internally of the PLC. The four system buses are:
Data bus is used by the CPU to transfer data among different elements.
Control bus transfers signals related to the action that are controlled internally.
Address bus sends the location’s addresses to access the data.
System bus helps the I/O port and I/O unit to communicate with each other.
SCADA
Supervisory control and data acquisition (SCADA) is a system of software and hardware elements that allows industrial organizations to:
Control industrial processes locally or at remote locations
Monitor, gather, and process real-time data
Directly interact with devices such as sensors, valves, pumps, motors, and more through human-machine interface (HMI) software
Record events into a log file
SCADA systems are crucial for industrial organizations since they help to maintain efficiency, process data for smarter decisions, and communicate system issues to help mitigate downtime.
The basic SCADA architecture begins with programmable logic controllers (PLCs) or remote terminal units (RTUs). PLCs and RTUs are microcomputers that communicate with an array of objects such as factory machines, HMIs, sensors, and end devices, and then route the information from those objects to computers with SCADA software. The SCADA software processes, distributes, and displays the data, helping operators and other employees analyze the data and make important decisions.
For example, the SCADA system quickly notifies an operator that a batch of product is showing a high incidence of errors. The operator pauses the operation and views the SCADA system data via an HMI to determine the cause of the issue. The operator reviews the data and discovers that Machine 4 was malfunctioning. The SCADA system’s ability to notify the operator of an issue helps him to resolve it and prevent further loss of product.
Who Uses SCADA?
SCADA systems are used by industrial organizations and companies in the public and private sectors to control and maintain efficiency, distribute data for smarter decisions, and communicate system issues to help mitigate downtime. SCADA systems work well in many different types of enterprises because they can range from simple configurations to large, complex installations. SCADA systems are the backbone of many modern industries, including:
Energy
Food and beverage
Manufacturing
Oil and gas
Power
Recycling
Transportation
Water and waste water
HMI
The Human Machine Interface (HMI) is the interface between the process and the operators – in essence an operator’s dashboard. This is the primary tool by which operators and line supervisors coordinate and control the industrial and manufacturing processes in the plant. HMIs serve to translate complex process variables into usable and actionable information.
Displaying near real-time operational information is the domain of the HMI. Visual process graphics give meaning and context to motor and valve status, tank levels and other process parameters. HMIs give operational insight into the process and enable control and optimization by regulating production and process targets.
HMI (Human Machine Interface) is a medium for information exchange and mutual communication between electromechanical system's and the user. It allows the user to complete settings through touchable images or keys on the user-friendly window. This not only offer's fast and convenient control of manufacturing automation, but also has replaced traditional controlling panel's which need extensive wiring.
Relay
A relay is an electrically operated switch. Many relays use an electromagnet to mechanically operate a switch. Relays are used where it is necessary to control a circuit by a separate low-power signal, or where several circuits must be controlled by one signal.
SSR
SSRs (Solid State Relays) have no movable contacts. SSRs are not very different in operation from mechanical relays that have movable contacts. SSRs, however, employ semiconductor switching elements, such as Thyristors, TRIACs, diodes, and transistors. Furthermore, SSRs employ optical semiconductors called photo couplers to isolate input and output signals. Photo couplers change electric signals into optical signals and relay the signals through space, thus fully isolating the input and output sections while relaying the signals at high speed.
SSRs consist of electronic parts with no mechanical contacts. Therefore, SSRs have a variety of features that mechanical relays do not incorporate. The greatest feature of SSRs is that SSRs do not use switching contacts that will physically wear out.
SSRs are ideal for a wide range of applications due to the following performance characteristics.
They provide high-speed, high-frequency switching operations.
They have no contact failures.
They generate little noise.
They have no operation noise.
Fuse
A fuse is an electrical safety device that operates to provide over current protection of an electrical circuit. It is essential component is a metal wire or strip that melts when too much current flows through it, thereby interrupting the current. It is a sacrificial device; once a fuse has operated it is an open circuit, and it must be replaced or rewired, depending on type.
Fuses have been used as essential safety devices from the early days of electrical engineering. Today there are thousands of different fuse designs which have specific current and voltage ratings, breaking capacity and response times, depending on the application. The time and current operating characteristics of fuses are chosen to provide adequate protection without needless interruption. Wiring regulations usually define a maximum fuse current rating for particular circuits. Short circuits, overloading, mismatched loads, or device failure are the prime reasons for fuse operation.
MCB
An MCB or miniature circuit breaker is an electromagnetic device that embodies complete enclosure in a moulded insulating material. The main function of an MCB is to switch the circuit, i.e., to open the circuit (which has been connected to it) automatically when the current passing through it (MCB) exceeds the value for which it is set. It can be manually switched ON and OFF as similar to normal switch if necessary.
MCBs are of time delay tripping devices, to which the magnitude of over current controls the operating time. This means, these get operated whenever overload exist long enough to create a danger to the circuit being protected. Therefore, MCBs doesn’t respond to transient loads such as switches surges and motor starting currents. Generally, these are designed to operate at less than 2.5 milliseconds during short circuit faults and 2 seconds to 2 minutes in case of overload.
Design: Analysis, Design methodology and implementation strategy
Key Partners
It includes those elements which are used to make or sell the products.
Power Plant
Boiler Making Companies
Automation provider
Electrical Components
Panel Makers
Key Activities
It includes activities involved in to prepare the product
Programming
Interfacing
Simulation
Wiring
Key Resources
It includes sectors we will be taking help for making or selling our product.
PLC making companies
Software providers
Electrical Components Suppliers
Value Proportion
It simply includes features of our product.
Human efforts reduces
Improve efficiency
Reliable
User friendly
Easy to maintain
Remote control
Customer Relationship
It includes factors which customer will experience with our product compare to other.
Cost effective
Easy to operate
More Accurate than any system
Channels
It includes way through which our product will be supplied.
Road
Truck
Trains supplying goods
Cost Structure
It includes component which will cost us to prepare our product.
PLC
Relays
RTD
SCADA software
SMPS for supply
Connecting cables and wires
Revenue Streams
It includes sectors from which we will get revenue for our product.
Boiler making companies
Power plant
Automation providers
Dying Industries
Customer Segment
Power plant
Boiler making Company
Implementation
Block Diagram
(1) Hardware
(2) Software
SCADA
HMI
We have added multiple screens through the programming
Multiple buttons are provided to jump to any screen just by pressing them so that other data can also be observe
We have used some indicators to indicate multiple processes like alarm on or blowers operation etc.
Slider is also provided to vary the set temperature value so limits can be changed
Screen 1 – It is an introductory screen touch button for all screens are designed on every screen so that one can observe any screen anytime they want.
Screen2 – It is screen provided to operate any relay output manually for HMI screen or from PC whatever is convenient
Screen3 – It is the screen provided to indicate temperature which we are measuring with the use of thermocouple .Data of thermocouple is given first to DTC module then it is taken to the HMI and PC, Set
Value can also be change through the slider provided display of temperature in digits and in terms of deflection is shown indication of alarm and blower is also provided on it.
PROJECT KIT
Thermocouple of J type is connected with the DTC module. Data from DTC module are collected and displayed on the HMI screen and PC .PC and PLC are interfaced through a ladder diagram so PLC will enable its outputs according to the ladder diagram made .Output components are connected with relay which will operate devices according the signal received from PLC.
Flowchart
Summary
Project was overall knowledge providing for us .Because form it we get a good knowledge of PLC system and visualization of same through the SCADA software. We learn how to interface devices with PLC and SCADA software .Form the DTC module we came to know that how we can interface temperature measuring devices. Interconnection of each module helps us to improve our skill and command over the system. We came to know about different software of different devices also.
Future is about automation only. It reduces the human interference and improves efficiency of the system also. It reduces the risk and hazardous situations that can be occur at the systems like boiler loosing it can cause high cost to the industry. PLC, SCADA and DCS for big industries are essential components for development and process of industry.
Advantages and Disadvantages:
Advantages
1) The accuracy of the system will increase, the precise temperature detection will takes place.
2) The mentoring system will faster, accurate and good. Due to which the performance of the system improves.
3) Multitasking, skilful work and speed action can be taken ob PLC system.
Disadvantages
1) Complexity will increase of connections.
2) Coding becomes hard to decode by persons.
3) Sentries devices should be take care about overvoltage coming in the system .(Mainly PLC)
Scope:
Boiler is one of the most important parts in any power plant. Which require continuous monitoring and inspection at frequent interval. In Power plants it has number of boiling section. This boiling section produces the high temperature water of the steam. Boiler steam temperature in thermal power plant is very complex and hard to control, due to poorly understand the working principles; Boilers have many serious injuries and destruction of property. It is critical for the safe operation of the boiler and the steam turbine. Too low a level may overheat boiler tubes and damage them. Too high a level may interfere with separating moisture from steam and transfers moisture into the turbine, which reduces the boiler efficiency.
Various controlling mechanism are used to control the boiler system so that it works properly, many control strategies have been applied to it. In order to automate a power plant and minimize human intervention, there is a need to develop a Boiler Automation system.
References:
1) https://www.ijirset.com/upload/2017/ncfcsps/41_50_Steam.pdf
2) http://ijarcet.org/wp-content/uploads/IJARCET-VOL-4-ISSUE-4-1653-1657.pdf
3) http://www.ijareeie.com/upload/2017/march/98_Boiler.pdf
4) https://www.ijirset.com/upload/2017/ncfcsps/41_50_Steam.pdf
5) https://www.ripublication.com/acst17/acstv10n6_30.pdf
APPENDIX:
PPR 1:
1) In the very initial Stage we made our basic layout of project in which we have categorized the equipment used and their specifications. We have visited places to gather information about the equipment and their availability.
2) Synchronization between the equipments according to their output levels and specifications was a difficult challenge for us. Also it was very difficult to get the equipments available at the local stores.
3) We needed the guidance of our mentor to help us out to find the synchronization between the equipments. After that we have talked to various technical persons from where to get the equipments cheaper.
4) http://www.delta.com.tw/product/em/control/plc/download/manual/DELTA_IA-PLC_DVP-ES2-EX2-SS2-SA2-SX2-SE-TP_PM_EN_20140704.pdf
http://www.delta.com.tw/product/em/control/plc/download/manual/Delta_PLC-Program_O_EN_20130530.pdf
http://www.deltaww.com/filecenter/Products/download/06/060302/Catalogue/DELTA_IA-HMI_DOP-Series_C_EN_20161202_web.pdf
PPR 2:
1. We have studied the programming language of PLC and purchases some of the equipments. We made the basic wiring diagram of our project and study it carefully.
2. Making a wiring diagram was difficult challenge for us. Also the programming language of PLC was new for us to understand.
3. We needed the help of technical person to teach us the ladder diagram of PLC. Also for wiring diagram we needed the help.
4. https://www.youtube.com/watch?v=kMrXWUOjwC8&list=PLMvbBtVgeVKfFaHNqROWDe2032WR845or
PPR 3:
1. We have learned the programming of delta PLC which we are using in our project. We have downloaded WPL soft software for delta PLC. We saw the basic working of our RTD module and relays and their interfacing with PLC. We downloaded the SCADA INtouch software.
2. Interfacing of RTD with PLC is a difficult challenge. Learning INtouch software is also a difficult task. Programming of WPL soft software was also difficult task to work with.
3. We took the help of sir of our institute to complete interfacing of RTD and PLC. We found software tutorials through which we can work on SCADA, from the internet.
4. https://www.youtube.com/watch?v=aNo2AaeobbE
https://www.youtube.com/watch?v=Glc0SNhOIio
PPR 4:
1. Finally we studied the SCADA software and prepared the layout of our project on INtouch software. We have completed interfacing between SCADA and PLC along with RTD and other devices. We made the whole simulation work. Also in hardware we have made a demo model to visualize whole thing very properly.
2. To make the project visualize in INtouch software was the most difficult task in the project. To make the hardware was also a difficult task to work on.
3. We needed the support of our sir to learn the scripting of INtouch software along with all connections. We were guided by our mentor for some of the changes to be made. We also took help of Internet to solve our queries.
4. https://www.omega.co.uk/Temperature/pdf/SEL_GUIDE_RTD.pdf
http://irtfweb.ifa.hawaii.edu/~iqup/domeenv/PDF/pt100plat.pdf
say in here…