masters presentation -process control- boiler and heat exchanger pilot plant

Motivation Modeling Pilot Plant Local Control Communication Control Conclusion Achievements

Design and Implementation of AdvancedControl Strategies for Boiler and Heat

Exchanger Pilot PlantGuided By:

Prof. S. D. Agashe

Ms. Tejaswinee J. DarureMIS: 121116004

June 26, 2013

Motivation

Academicians seldom get exposure to the actual industrialenvironment.

Access to various control platforms under one roof is unavailable,for evaluation, comparison, etc.

Real-time data if available can be monumental in online/oinedata analysis exercises.

Motivation

Objectives

1 Mathematical Modeling for Boiler and Heat Exchanger PilotPlant

2 Concept to commissioning of Boiler and Heat Exchanger PilotPlant

3 Control from multiend and multiuser

Objectives

Outline

1 Mathematical ModelingBoiler

Heat Exchanger

2 Pilot Plant Insight

3 CommunicationControlLogix

MATLAB

DeltaV DCS

4 ControlPID Controller

Model Predictive Control

5 Conclusive Discussion

Outline

Heat Exchanger

MATLAB

DeltaV DCS

Boiler

Material Balance Equations:-

Mass Balance

d

dt{sVst + wVwt} = qf qs

Energy Balance

d

dt{susVst + wuwVwt +mtCptm} = Q+ qfhf + qwhw

Boiler

Material Balance Equations:-

Mass Balance

d

dt{sVst + wVwt} = qf qs

Energy Balance

d

dt{susVst + wuwVwt +mtCptm} = Q+ qfhf + qwhw

Boiler

After solving,

dVwtdt

=Qm12 + wqw (hfm12 m22) sqs (hsm12 m22)

(m12m21 m11m22)dp

dt=

wqw sqs m11 dVwtdtm12

where:

m11 = (w s)m12 = (Vd Vwt) ds

dp+ Vwt

dsdp

m21 = (whw shs)m22 = (Vd Vwt)

(sdhsdp

+ hsdsdp

)+ wVw

dhsdp

Boiler

After solving,

dVwtdt

=Qm12 + wqw (hfm12 m22) sqs (hsm12 m22)

(m12m21 m11m22)dp

dt=

wqw sqs m11 dVwtdtm12

where:

m11 = (w s)m12 = (Vd Vwt) ds

dp+ Vwt

dsdp

m21 = (whw shs)m22 = (Vd Vwt)

(sdhsdp

+ hsdsdp

)+ wVw

dhsdp

Boiler

Figure: Simulation in MATLAB Simulink for Boiler

Heat Exchanger

Figure:Countercurrent HeatExchanger

1 Shell side(Outer Pipe)

1 Fluid2 Flow rate3 Temperature

2 Tube side(Inner Pipe)

3 FlowConfiguration

As there is no mass accumulation so mass balance does not apply inHeat Exchanger

Heat Exchanger

3 FlowConfiguration

Heat Exchanger

3 FlowConfiguration

Heat Exchanger

3 FlowConfiguration

Heat Exchanger

3 FlowConfiguration

Figure: Simulation in MATLAB Simulink for Heat Exchanger

Figure: Combined Model

Outline

Heat Exchanger

MATLAB

DeltaV DCS

BOILER

CENTRIFUGAL PUMPPOSITIVE

DISPLACEMENT

PUMP

TSHH PWM Controller

PSHH

LT

LSLL1

VFD1

VPLC

I/P

TT1

TT2

VPLC

VFD2

FT

TT3

LSLL3LSLL2

LSLL4

LSHH2

LSHH1

PT

BOILER FEED WATER

TANKCOLD WATER TANK

HOT WATER TANK

CONDESATE

TANK

HEAT EXCHANGER

SOLENOID VALVE

FROM 3-PHASE SUPPLY

NOTE: AREA INSIDE THE DARK BOX NOT IN VENDORS SCOPE

Figure: Process and Instrument Diagram

Figure: Boiler and Heat Exchanger Pilot plant Pilot Plant

1 Level of water in the boiler drum (LT-1)

2 Drum pressure (PT-1)

3 Steam temperature (TT-1)

4 Boiler feed water temperature (TT-5)

5 Boiler feed water flow ((FT-2)

6 Temperature from water from hot water tank for mixing withboiler feed water (TT-4)

7 Steam flow (FT-3)

8 Heat exchanger steam inlet temperature (TT-2)

9 Heat exchanger water inlet temperature (TT-4)

10 Heat exchanger water outlet temperature (TT-3)

11 Heat exchanger water flow (FT-1)

Figure: Process and Instrument Diagram

Local Control

Figure: Local Controllers

Outline

Heat Exchanger

MATLAB

DeltaV DCS

Communication Overview

Figure: Network Topology

ControLogix

About ControLogix

Chassis Based Series 1756-L61RSlinx

ControLogix

About ControLogix

Chassis Based Series 1756-L61

RSlinx

ControLogix

About ControLogix

ControLogix

About ControLogix

ControLogix

RsLogix 5000

RSview Works

Procedure

Ethernet IP protocol

ConfigurationIP address: 169.254.104.223Subnet mask: 255.255.0.0

Messaging

ControLogix

RsLogix 5000

RSview Works

Procedure

Messaging

ControLogix

RsLogix 5000

RSview Works

Procedure

Messaging

ControLogix

RsLogix 5000

RSview Works

Procedure

Configuration

IP address: 169.254.104.223Subnet mask: 255.255.0.0

Messaging

ControLogix

RsLogix 5000

RSview Works

Procedure

Messaging

ControLogix

Figure: Messaging for AI and DI

ControLogix

Figure: Messaging for AI and DI

ControLogix

Figure: Flow for PLC program

ControLogix

Modbus RTU

Serial Communication Protocol

Protocol Data Unit (PDU)

Application Data Unit (ADU)

Figure: Data packet format in Modbus RTU

Modbus RTU

Figure: Client Server topology

Modbus RTU

Configuration Parameters

Sr.No. Parameter Value1 Baud Rate (bits/sec) 192002 Parity None3 Stop bit 14 Data Bits 85 Time out 0.1sec

Table: Configuration for Serial Port

MATLAB

Initialization of serial port

s=serial(COM1);set(s,BaudRate,19200)set(s,Timeout,0.1)get(s)fopen(s); this opens the portfcloses; this opens the port

Read Data

txdata=gen-pdu-read(AI/DI Mod-bus address)fwrite(s,txdata,uint8)rxdata-dec=fread(s)

Write Data

txdata=gen-pdu-write(AO/DOModbus address,value)fwrite(s,txdata,uint8)

DeltaV DCS

Figure: Location of Serial Card in DeltaV

DeltaV DCS

Figure: Adding new device:Micrologix 1400 PLC

DeltaV DCS

Figure: Device address and description of slave

DeltaV DCS

Figure: New Device added

DeltaV DCS

Figure: Create dataset in DelatV Tag

DeltaV DCS

Figure: Define description and data direction

DeltaV DCS

Figure: define PLC data type and register offset and number

DeltaV DCS

Figure: Add DeltaV data type and tag name foe dataset

DeltaV DCS

Figure: Example for data tag name

DeltaV DCS

Figure: Table of Registers created

Thus data can be written and read in each end:-

1 Micrologix PLC

2 Contrologix PLC using Ethernet IP protocol

3 MATLAB/VPLC/VDCS using MODBUS protocol

4 DeltaV DCS using MODBUS protocol

Outline

Heat Exchanger

MATLAB

DeltaV DCS

Plant Control

Sr.No. Controlled Variable Manipulated Variable1 Boiler Level Feed Pump Speed

OrSteam flow rate

2 Boiler Temperature SCR3 Heat Exchanger Outlet Temperature Cold water pump speed

OrControl Valve

Table: List of controlled and corresponding manipulated variable

VDCS

Control through ControLogix

Routines and their scope

SR.No. Routine Name Function1 Main decides execution sequence2 Data In real time data is received through messaging3 Interlock check for low and high limits4 Plant mode plant start and stop control5 Control Logic implementation controllers (PID)

Table: Routines and their scope

Figure: Run ans Stop mode for plant

Interlocks for safety

SR.No. Process Variable Limit Corrective action1 LT-1 75% Heater OFF2 TT-1 1450C Heater OFF3 PT-1 3.7 bar Heater OFF4 LSH-201 =1 Pump-301 OFF5 LSH-101 =1 Pump-101 OFF

Table: Interlock with corresponding action

View in RsLogix5000

Figure: Run ans Stop mode for plant

PID block

Figure: PID controller implemented in FBD programming

PID block

Figure: PID controller implemented in Ladder programming

Data Logging

Data Logging setup

SCADA

Figure: SCADA in RSView32 Works

Control through DeltaV DCS

Figure: Plant Mode in DCS

Figure: Location of Boiler and Heat Exchanger

Figure: PID implementation in Control Studio

Figure: Trends in Process History View

Figure: Graphics developed in Operate figure

Figure: TuneInsight tool

Model Predictive Control Overview

MPC includes following ideas,

1 Explicit use of a model to predict the process output along afuture time horizon

2 Calculation of a control sequence to optimize a performance index

3 A receding horizon strategy, so that at each instant the horizon ismoved towards the future, which involves the application of thefirst control signal of the sequence calculated at each step.

MPC in DeltaV DCS

Outline

Heat Exchanger

MATLAB

DeltaV DCS

Conclusive Discussion

The pilot plant is interfaced through various controllers usingModbus 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 drivenmodeling, where samples were collected at each-end irrespectiveof active or passive master.

For instant analysis, online trends are also configured at everyend.

Goals Achieved

1 Unit Operation Insight

2 Mathematical Modeling of Boiler and Heat Exchanger

3 Installation and Testing of hardware

4 Local Control Capability

5 Serial Communication of plant to PC/DCS using Modbus RTUprotocol

6 Communication with ControLogix using Ethernet/IP protocol

7 Plant Safety

8 Daisy Chaining for ControLogix and DCS

9 Control strategies at each-end

10 Testing and Control through VPLC and VDCS

11 Implementation of control strategies on setup (Partially)

Goals Achieved

7 Plant Safety

Goals Achieved

7 Plant Safety

Goals Achieved

7 Plant Safety

Goals Achieved

7 Plant Safety

Goals Achieved

7 Plant Safety

Goals Achieved

7 Plant Safety

Goals Achieved

7 Plant Safety

Goals Achieved

7 Plant Safety

Goals Achieved

7 Plant Safety

Goals Achieved

7 Plant Safety

Thank You

Mathematical ModelingBoilerHeat Exchanger

Pilot Plant InsightCommunicationControlLogixMATLABDeltaV DCS

ControlPID ControllerModel Predictive Control

Conclusive Discussion

masters presentation -process control- boiler and heat exchanger pilot plant

Documents

various control platforms

mass balanceddt

actual industrialenvironment

realtime data

qf qsenergy balanceddt

susvst wuwvwt mtcptm

svst wvwt