Industrial Automation and Control of DCS linked Fire Tube Boiler
Harnessing steam power has been credited as being probably the most important technological advancement to have contributed to the rise of industrial nations. Steam power is the key to the Industrial Revolution even in this era, and boilers continue to dominate as a power source.
Project Title
Industrial Automation and Control of DCS linked Fire Tube Boiler
Project Area of Specialization
Project Summary
Harnessing steam power has been credited as being probably the most important technological advancement to have contributed to the rise of industrial nations. Steam power is the key to the Industrial Revolution even in this era, and boilers continue to dominate as a power source.
Boilers are used to produce steam which is then used for different operations such as to run the turbine which in turn produces electricity or it may be supplied at low pressure for industrial process work in cotton mills, sugar industries and for the production of hot water which can be used for heating installations. During this process, it is essential to monitor the parameters: temperature, steam pressure, water level for reliable operation. But with the human workers there are number of possibilities of errors while measuring at different stages. The boiler automation techniques are very much important to avoid these errors and hazardous damages. The target for the boiler automation is to take care of the boiler safety and to prevent dangerous condition’s occurrences, hence it must be fast and informative. The important prerequisite to ensure the good and safe operation of industrial processes, i.e. a boiler, is control system performance analysis, assessment, diagnostic and monitoring.
Project Objectives
- The primary objective is to automate the hard-wired relay-based standalone fire tube boiler which is linked to DCS in Engro Polymer and Chemicals. The boiler is used for the production of steam with temperature, pressure, and level as control parameters.
- Selection of a suitable brand PLC according to our requirements and needs from a wide variety of brands.
- Converting the relay-based system to a PLC controlled network by developing a certain logic, keeping in mind the safety precautions.
- Link Burner Management System (BMS) to the new automated system.
- Designing and selection of HMI for controlling and monitoring purposes.
- Installation of PLC and HMI.
Project Implementation Method
Task 1: Literature review of an Industrial Boiler, its Management, and Subroutines.
Task 2: Understanding the operation and interfacing of different sensors, actuators, and drives.
Task 3: Developing an algorithm for Burner Management System (BMS), in addition to the PLC logic (which may be ladder, FBD or STL) for sensors and actuators.
Task 4: Simulating the developed algorithm.
Task 5: Integration of Human Machine Interface (HMI) and testing it through simulation.
Task 6: Establishing a comprehension of Distributed Control System (DCS) followed by linking the project to the existing DCS at the site.
Task 7: Hardware selection and purchasing.
Task 8: Designing of Control Panel.
Task 9: Actual Implementation at the Industry.
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Benefits of the Project
Good performance of the control system is the safe and stable foundation of the excellent operation of industrial processes. It is very significant to improve product quality, increase production efficiency, reduce the consumption of raw materials and energy consumption and prolong the service life of the equipment. Therefore, automation will enhance all these factors in addition to providing automatic control of the boiler.
Technical Details of Final Deliverable
Complete Control Panel will be submitted which will contain PLC (Controller) and it's associated equipment of industrial level along with an HMI on the front end of the Control Panel
Final Deliverable of the Project
Core Industry
Other Industries
Core Technology
Other Technologies
Sustainable Development Goals
Required Resources
| Elapsed time in (days or weeks or month or quarter) since start of the project | Milestone | Deliverable |
|---|---|---|
| Month 1 | Literature review of an Industrial Boiler, its Management and Subroutines. | Review Paper |
| Month 2 | Understanding the operation and interfacing of different sensors, actuators and drives. | Nothing |
| Month 3 | Developing an algorithm for Burner Management System (BMS), in addition to the PLC logic (which maybe ladder, FBD or STL) for sensors and actuators. | Nothing |
| Month 4 | Simulating the developed algorithm. | Nothing |
| Month 5 | Designing of Control Panel and Actual Implementation at the Industry | Control Panel |
| Month 6 | Analyzing the real-time performance of the Boiler. | Nothing |
| Month 2 | Understanding the operation and interfacing of different sensors, actuators and drives. | Nothing |
| Month 3 | Developing an algorithm for Burner Management System (BMS), in addition to the PLC logic (which maybe ladder, FBD or STL) for sensors and actuators. | Nothing |
| Month 4 | Simulating the developed algorithm. | Nothing |
| Month 5 | Designing of Control Panel and Actual Implementation at the Industry | Control Panel |
| Month 6 | Analyzing the real-time performance of the Boiler. | Nothing |
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