Application of IoT and AI in process-industry - Ashish Nimsarkar , DGM(C&I), NTPC Ltd.

Korba

This paper describes a possible application of IoT (Internet of Things) and artificial intelligence in
Coal based thermal power plants. As such, this can be a possible application in any process plant.

Given below is a typical arrangement of a pneumatic-actuator which controls a Hot-air damper.

CM – Communication Module , it talks with sensors and positioner and communicates the data to
the IoT network.

IoT network shall be a totally separate network from plant DCS network.

Data Transmission rates : Sensor – CM : 0.1 sec cycle time

CM – Router : 01 sec. , cycle time

SMART Pressure-sensors, Temperature-sensors, Torque-sensors,Motion sensors and SMART

positioners are used in this scheme.

Features of a typical SMART sensor are given below

1.Wireless sensor with chargeable battery.

2.Wireless communication technolgy can be Bluetooth/IR or Wi-fi based.

3. Wireless communication technolgy shall be suitable for environments with electrical noises
generated by HT and LT electrical equipments.

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Application of IoT and AI in process-industry - Ashish Nimsarkar , DGM(C&I), NTPC Ltd. Korba

4.SMART sensors shall have built-in temperature-compensation feature.

5.SMART sensors should work satisfactorily in

5.1 highly dusty environments with heavy fly-ash and coal-dust.

5.2 ambient temperatures upto 50 degC (continuous) and occassional high temperatures upto
75degC (for 20-30 min.)

5.3 occassional water showers

5.4 mild vibrations

6.SMART sensors should have self diagnostic facilities like

6.1 Periodic validation/calibration reminder message

6.2 low-battery message

6.3 sensor temperature High alarm.

7. SMART sensors should have the capability to cross-verify its values with nearby similar sensors.

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Application of IoT and AI in process-industry - Ashish Nimsarkar , DGM(C&I), NTPC Ltd. Korba

A typical pressure sensor mounting arrangement is shown below

Similar arrangement can be done for pressure-sensor mounting on Positioner (PNR).

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Application of IoT and AI in process-industry - Ashish Nimsarkar , DGM(C&I), NTPC Ltd. Korba

Details of a SMART positioner

CMPNR – Communication Module within the positioner.

Present Standard SMART positioner New additions for IoT

A digital processor
FS-Feedback sensor (feedback from actuator
position)
Fb – Feedback signal to DCS
Cs – Command signal from DCS
CMPNR – Communication Module within the
positioner.
P3, P4,P5 – pressure sensors
T2 – Temperature sensor
Inorder to prevent loading of the Processor ,
additional sensors P3,P4,P5,T2 directly
communicate with CMPNR

Data flow from Processor to CMPNR

FS - feedback from actuator position

Fb – Feedback signal to DCS

Cs – Command signal from DCS

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Application of IoT and AI in process-industry - Ashish Nimsarkar , DGM(C&I), NTPC Ltd. Korba

Details of motion sensor

Although the positioner (PNR) is sensing the actuator position through feedback linkage, additional
position data is required to cross-verify the actuator position and take decisions.

Some decision making logics are described below : -

▪ At AFR (air filter regulator)

If (P1-P2) > 3 Kg/csm2 , then AFR choking

Exceptions:

1.assuming no port-leakages

2.assuming no vessel leakages

3.assuming no leakage from drain port.

▪ Between AFR and PNR (positioner)

If P2-P3 > 0.1 Kg/cm2, then Air-supply side air-leakage in air-tube/fitting.

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Application of IoT and AI in process-industry - Ashish Nimsarkar , DGM(C&I), NTPC Ltd. Korba

▪ At PNR (positioner) side

“Piston Extend command” can be taken from PNR-processor, via CMPNR

If “Piston Extend command” to PNR (positioner)

& P5-P7 > 0.1 Kg/cm2 , then actuator-downside air-tube/fitting air-leakage

▪ At Actuator side

If “Piston Extend command” to PNR (positioner)

& P7-P6 < 2 kg/cm2 , then Actuator-passing

This can be further confirmed , IF T1 > 60 degC for last 48 hours

▪ At Actuator side

If “Piston Retract command” to PNR (positioner)

& P6-P4 < 0.1 Kg/cm2 (no air-tube leakage)

& P7 < 1 Kg/cm2 (no actuator passing)

& P6 < 2 Kg/cm2

Then Actuator gland-leakage.

▪ At actuator shaft side

Let Normal Torque = tn (value to be decided from normal observation)

If at any time, Tq > tn

And Tq-tn > 0.2tn , (applied torque is 20% higher than normal torque)

Then “Damper jamming”

▪ At actuator shaft side

If T1 > 50 degC for time=30 min.

Then “Hot air duct leakage”

▪ At PNR (positioner) side

If “Piston Extend command” to PNR (positioner)

& P5 = 0 OR P5 < 1Kg/cm2 ( 0 or very low pressure at positioner output port)

& P5-P7 < 0.1 Kg/cm2 (no air-tube leakage)

Then “PNR (positioner) malfunction”

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Application of IoT and AI in process-industry - Ashish Nimsarkar , DGM(C&I), NTPC Ltd. Korba

▪ At PNR (positioner) side

If Fs = M (positioner feedback sensor signal-Fs and Motion sensor signal-M are matching)

& Fb ≠ Fs ( Fb-positioner feedback signal , 4-20mA, to DCS and Fs-signal from positioner feedback
sensor are mismatch)

Then positioner feedback circuit fault.

▪ At PNR (positioner) side

If Fs = Fb

& Fs ≠ M

Then positioner feedback linkage error.

Note : Constants used in above logics are arbitrary. They are to be finalized on case-to-case basis.

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