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Masters Presentation - Process Control - Boiler and Heat Exchanger Pilot Plant
Masters Presentation - Process Control - Boiler and Heat Exchanger Pilot Plant
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Design and Implementation of Advanced Control Strategies for Boiler and Heat Exchanger Pilot Plant
Guided By: Prof. S. D. Agashe
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Academicians seldom get exposure to the actual industrial environment. Access to various control platforms under one roof is unavailable, for evaluation, comparison, etc.
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Academicians seldom get exposure to the actual industrial environment. Access to various control platforms under one roof is unavailable, for evaluation, comparison, etc. Real-time data if available can be monumental in online/oine data analysis exercises.
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Objectives
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Objectives
Mathematical Modeling for Boiler and Heat Exchanger Pilot Plant Concept to commissioning of Boiler and Heat Exchanger Pilot Plant
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Objectives
Mathematical Modeling for Boiler and Heat Exchanger Pilot Plant Concept to commissioning of Boiler and Heat Exchanger Pilot Plant Control from multiend and multiuser
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Outline
Conclusive Discussion
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Outline
Conclusive Discussion
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Boiler
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Boiler
Material Balance Equations:Mass Balance d {s Vst + w Vwt } dt Energy Balance d {s us Vst + w uw Vwt + mt Cp tm } dt = Q + qf hf + qw hw = qf qs
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Boiler
After solving, dVwt dt dp dt where: = = Qm12 + w qw (hf m12 m22 ) s qs (hs m12 m22 ) (m12 m21 m11 m22 )
wt w qw s qs m11 dV dt m12
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Boiler
After solving, dVwt dt dp dt where: m11 m12 m21 m22 = = ( w s ) (Vd Vwt ) = = Qm12 + w qw (hf m12 m22 ) s qs (hs m12 m22 ) (m12 m21 m11 m22 )
wt w qw s qs m11 dV dt m12
+ w V w
dhs dp
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Boiler
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Heat Exchanger
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Heat Exchanger
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Heat Exchanger
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Heat Exchanger
3 3
Flow Conguration
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Heat Exchanger
3 3
Flow Conguration
As there is no mass accumulation so mass balance does not apply in Heat Exchanger
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Outline
Conclusive Discussion
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
VPLC
TT1
LSHH2
PT
I/P
TT2
TSHH
PWM Controller
HEAT EXCHANGER
LSLL4 PSHH
LT
BOILER
CONDESATE TANK
VPLC VPLC
VFD1
VFD2
LSLL2
CENTRIFUGAL PUMP
LSLL3
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
1 2 3 4 5 6
Level of water in the boiler drum (LT-1) Drum pressure (PT-1) Steam temperature (TT-1) Boiler feed water temperature (TT-5) Boiler feed water ow ((FT-2) Temperature from water from hot water tank for mixing with boiler feed water (TT-4) Steam ow (FT-3) Heat exchanger steam inlet temperature (TT-2) Heat exchanger water inlet temperature (TT-4) Heat exchanger water outlet temperature (TT-3) Heat exchanger water ow (FT-1)
7 8 9 10 11
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Local Control
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Outline
Conclusive Discussion
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Communication Overview
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
About ControLogix
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
About ControLogix
Chassis Based Series 1756-L61
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
About ControLogix
Chassis Based Series 1756-L61 RSlinx
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
About ControLogix
Chassis Based Series 1756-L61 RSlinx
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
RsLogix 5000
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
RsLogix 5000 RSview Works Procedure Ethernet IP protocol Conguration IP address: 169.254.104.223 Subnet mask: 255.255.0.0 Messaging
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
ControLogix
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Modbus RTU
Serial Communication Protocol Protocol Data Unit (PDU) Application Data Unit (ADU)
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Modbus RTU
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Modbus RTU
Conguration Parameters Sr.No. 1 2 3 4 5 Parameter Baud Rate (bits/sec) Parity Stop bit Data Bits Time out Value 19200 None 1 8 0.1sec
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
MATLAB
Read Data Initialization of serial port s=serial(COM1); set(s,BaudRate,19200) set(s,Timeout,0.1) get(s) fopen(s); this opens the port fcloses; this opens the port txdata=gen-pdu-read(AI/DI Modbus address ) fwrite(s,txdata,uint8) rxdata-dec=fread(s)
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Figure: dene PLC data type and register oset and number
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Figure: Add DeltaV data type and tag name foe dataset
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
DeltaV DCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Micrologix PLC Contrologix PLC using Ethernet IP protocol MATLAB/VPLC/VDCS using MODBUS protocol DeltaV DCS using MODBUS protocol
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Outline
Conclusive Discussion
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Plant Control
Sr.No. 1
2 3
Manipulated Variable Feed Pump Speed Or Steam ow rate SCR Cold water pump speed Or Control Valve
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
VDCS
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Routines and their scope SR.No. 1 2 3 4 5 Routine Name Main Data In Interlock Plant mode Control Logic Function decides execution sequence real time data is received through messaging check for low and high limits plant start and stop control implementation controllers (PID)
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Interlocks for safety SR.No. 1 2 3 4 5 Process Variable LT-1 TT-1 PT-1 LSH-201 LSH-101 Limit 75% 1450 C 3.7 bar =1 =1 Corrective action Heater OFF Heater OFF Heater OFF Pump-301 OFF Pump-101 OFF
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Explicit use of a model to predict the process output along a future time horizon Calculation of a control sequence to optimize a performance index A receding horizon strategy, so that at each instant the horizon is moved towards the future, which involves the application of the rst control signal of the sequence calculated at each step.
2 3
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Outline
Conclusive Discussion
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Conclusive Discussion
The pilot plant is interfaced through various controllers using Modbus RTU and Ethernet/IP without any loss in data. Data is available for sampling periods upto 100 ms. Safety is taken into account at each controller-end. GUIs are developed with a capability to display real time values. Rigorous Database is created for analysis and data driven modeling, where samples were collected at each-end irrespective of active or passive master. For instant analysis, online trends are also congured at every end.
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger
1 2
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware
1 2 3
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability
1 2 3 4
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol
1 2 3 4 5
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol
1 2 3 4 5
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety
1 2 3 4 5
6 7
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety Daisy Chaining for ControLogix and DCS
1 2 3 4 5
6 7 8
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety Daisy Chaining for ControLogix and DCS Control strategies at each-end
1 2 3 4 5
6 7 8 9
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety Daisy Chaining for ControLogix and DCS Control strategies at each-end Testing and Control through VPLC and VDCS
1 2 3 4 5
6 7 8 9 10
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety Daisy Chaining for ControLogix and DCS Control strategies at each-end Testing and Control through VPLC and VDCS Implementation of control strategies on setup (Partially)
1 2 3 4 5
6 7 8 9 10 11
Motivation
Modeling
Pilot Plant
Local Control
Communication
Control
Conclusion
Achievements
Thank You