MAIN PROJECT PRESENTATION 2012

THANGAL KUNJU MUSALIAR INSTITUTE OF TECHNOLOGY

GUIDED BY
Mrs. BeenaRani B B Lect. EI Dept.

PRESENTED BY
Anju J [ 8406 ] Arya M S [ 8412 ] Devika S [ 8420 ] Neethu Raj [ 8434 ]

Sibimol Luke [ 8449 ]

DONE AT
The Kerala Minerals and Metals Ltd.Chavara, Kollam

INTRODUCTION

Boiler is a steam generating unit. AIM- Controlling water level in boiler drum. 3 control strategies :single element. two element and three-element control

3 element control implemented using embedded programmable controller Yokogawa YS1700.

BOILER

A closed vessel made of steel in which water or other fluid is

heated to generate steam.

Slave plant or utility plant and it is maintained at negative pressure Used to generate steam for doing mechanical work, heating, producing vacuums, and augmenting chemical processes An important variable to measure and control in a continuous boiler is the level of water in the steam drum This vessels primary function is to provide a surface area and volume near the top of the boiler where separation of steam from water can occur

WATER TUBE BOILER

Used for high steam demand and pressure requirements Capacity range of 4,500 120,000 kg/hour

Combustion efficiency enhanced by induced draft provisions

Lower tolerance for water quality and needs water treatment plant

BOILER IN KMML

BOILER BLOCK DIAGRAM

DM WATER
TANK DEAERATOR ECONOMISER

BOILER DRUM

STEAM

BOILER AIR SCHEME

AIR

FD FAN

DAMPER

WIND BOX

OIL

BURNER

FLAME

BOILER FUEL SCHEME

OIL STORAGE TANK OIL CONTROL VALVE

OIL HEATER

BURNER

DRUM LEVEL CONTROL

OBJECTIVE OF THE PROJECT

Operator adjustment of the set point. Compensation for the shrink and swell effects. Automatic control of drum level. Bump less transfer between auto and manual modes. Indication of drum level and steam flow. Indication of feed water valve position and feed water flow.

Absolute/deviation alarms for drum level.

SINGLE ELEMENT CONTROL

MEASUREMENT

PID

CV

SET POINT

Single-Element control is the simplest strategy Single element drum level control measures drum level only This is a simple feedback control loop Only one analogue input and one analogue output required Can only be applied to single boiler / single feed pump configurations with relatively stable loads since there is no relationship between drum

level and steam- or feed water flow

Possible inadequate control option because of the swell effect During startup of a boiler, it is effective to use single-element control in

which the feed water controller is bypassed and the drum level
controller directly controls the feed water control valve

TWO ELEMENT CONTROL

LEVEL

INFLOW

PV SET SET POINT PID PID

PV

CV
15

The two element control scheme utilizes steam flow in addition to drum level

This is a simple feedback plus feed forward control system with a secondary variable that has a predictable relationship with the manipulated variable

The secondary variable, steam flow, causes the manipulated variable to change the primary variable

Tighter control of drum level than with only one element Steam flow acts as feed forward signal to allow faster level adjustments Can best be applied to single boiler / single feed pump configurations with a constant feed water pressure

THREE ELEMENT CONTROL

DRUM LEVEL

SAT FLOW

SUP FLOW

WATER FLOW

LAG PV

ADD PV

SET SET PID MATH PID CV

Three element control utilizes steam and water flow in addition to drum level

This is a simple feedback, feed forward, and cascade control loop. The steam flow adjusts the feed water control valve based on the steam flow signal and the drum level controller signal

The three-element system provides tighter control for drum level with fluctuating steam load.

Ideal where a system suffers from fluctuating feed water pressure or flow

More sophisticated level of control required Additional input for feed water flow required

SCHEMATIC DIAGRAM

PERFORMANCE
Single element Two element Three element

APPLICATION CHART FOR DRUM LEVEL CONTROL SYSTEM

System Classification Load Change Capabilities Typical Applications

Magnitude
Single-element Moderate

Rate
Slow Institutional and industrial heating plants Steady process conditions

Two-element

Moderate

Moderate Industrial plants with essentially continuous type processes and good feed water pressure regulation

Three-element

Wide

Fast

Combination of batch and continuous type operations such that plant steam load characteristics varies continuously and usually unpredictably. Most industrial power applications fall into this category.

EMBEDDED SYSTEM

Embedded Systems is a special purpose computer system/board, which encapsulates all the devices such as processor, memory, interface and

control in single package or board to perform only a specific application

tasks.

EXISTING CONTROLLER BCE 760

Single station ,single loop controllers having P, PI, PID functions.

LIMITATIONS Dedicated registers. So it cannot be used for other purposes.

Lag cannot be provided directly.

No peer to peer communication. It can do only one control action.

No graphical monitoring is possible.

Cannot be employed in emergency situations.

YOKOGAWA YS1700 PROGRAMABLE CONTROLLER

YS1700 is a programmable logic controller

Each YS1700 can run two PID control

algorithms, and the corresponding 4 ~ 20mA output signal

YS1700 can also be used without programming multi-function controller

The YS1700 Programmable Indicating Controller includes over one-hundred

computation modules

RS-485 communication protocol for the YS1000 series

FEATURES

Function block programming: GUI-based programming method.

Large programming capacity. More powerful control and calculation functions. Function selection mode (needs no programming). Expandable I/O. Nonvolatile memory for memory backup. Dual power supply.

YSS 1000 SOFTWARE BASIC OPERATION

FLOW CHART
START

READ DRUM LEVEL

READ SAT FLOW

READ SUP FLOW

READ FEED WATER FLOW

X GAIN + BIAS

X GAIN + BIAS

X GAIN + BIAS

X GAIN + BIAS

DLC MODE = MANUAL

NO

SUM FIC MODE = AUTO YES C = A+B PI ALGORITHM NO

YES MV = MAN O/P SET = PV PI ALGORITHM

FIC MODE = MANUAL YES MV = MAN O/P SET = PV

SUM - 50

NO

C = SET

FW_CV

END

PROGRAM

Program for Three Element Control

LD X4; drum level signal LD P8; gain * LD P9; bias + ST T16;

LD P1; first order lag time in second

LAG 1 ST T1

ST Y2; retransmission drum level to recorder A02 LD X3; feed water flow signal LD P10; gain * LD P11; bias + ST T2 ST P30; to display feed water flow in drum level controller face plate

LD X1; sat steam flow signal

LD P2; 0.666 gain for ranging *

ST T3 LD X2; super heated steam flow LD P3; 0.333 gain for ranging * ST T4 LD T3

+
ST T5 ST Y3; for pressure controlling flow feed forward signal AO3 ST P6; for display total steam flow in feed water controller face plate

LD P4; gain of total steam flow for correction if necessary now it is 1

* LD P5; 50 %( subtractor from drum level cont4roller output ST T6 ST FF1; feed forward signal modify drum level controller output by T6

LD SV2; six lines after this is for ascertaining the drum level controller output in T15

LD P6 -

ST T14 LD P5 + ST T15 LD DI1; 1=single element,0=three element LD P7; 100=single element, 0=three element OR ST PRDF; true= (single element), false= (three element) LD CAMF1; true when controller1 LIC in auto mode NOT GIFSUB @ abc; jump to subroutine 4 trading the PV by SV of LIC in manual mode

LD T1; compensated drum level

LD T2; feed water flow CSC; cascade ST Y1; output to feed water control valve LD PHF1; true when high level alarm occurs ST DO3; digital output of high alarm LD PLF1; true when low level alarm occurs ST DO2; digital output of low alarm LD X1 ST P12 LD X2 ST P13

LD T2 ST P14 LD T1 ST P15 LD T15 ST P16

LD CAMF2
NOT GIFSUB @ def END; end of main program SUB@abc

LD PV1 ST SVI RTN SUB @ def LD PV2 ST SV2

RTN
SUB @ SIMPR; test program LD P21 ST X1 LD P22

ST X2 LD P23 ST X3 LD P24 ST X4 RTN

CONCLUSION

Successfully controlled the boiler drum level using YS1700 programmable controller.