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8/7/2019 AUTOMATION OF BMS SYSTEM OF BOILER USING PLC LADDER LOGIC
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AUTOMATION OFBMS SYSTEM OF
BOILER USING
PLC LADDER LOGIC
Authorised By
SANTOSH BHARADWAJ REDDYEmail: help@matlabcodes.com
Engineeringpapers.blogspot.com
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ABSTRACTThe problem of operation and safety posed by a Recovery Boiler is much
more than a conventional utility/Industrial Boiler. The Black Liquorfrom Pulp Mill is acquired by Evaporator which is sent to Liquor Fired
Boiler.
Recovery Boiler is basically a chemical recovery process unit where the
organic material in the black liquor is burnt, while the sodium salt isreduced and drained as molten smelt from the furnace bottom.
At the same time, Super Heated Steam which is the byproduct is utilized
for steam generation. Flue Gas is sent out through Chimney through I.D
Fan. The Green Liquor is sent to Causticizing Plant for Generation ofWhite Liquor.
The BMS System is a part of LIQUOR FIRED BOILER(LFB 5) of Soda
Recovery Plant. HoneyWell PLC is used to study the BMS System in
BOILER Plant..
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In LFB5 the BMS system includes Primary, Secondary/Tertiary fans,
Liquor Guns, Oil Burner Valves, Induced Draft Fan, Electrostatic
Precipitator, Economizers, Steam/ Mud Drum, Furnace and Pumps to
circulate water .
In BMS system the Furnace is first Purged completely i.e., to flush the
Furnace with fresh air. In this duration of Purging (120ms) all valves
should be closed.
The BMS provides for the proper sequencing of equipment during the
normal startup operating and shut down procedures and provides for an
auxiliary fuel trip and/or an alarm during an adverse burner or unit
operating condition.
This is accomplished through the use of pre-wired logic and various
Interlocks.
The Industrial parameters like Temperature, Pressure, Flow, Level are
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The Implementation section includes Level Control in a Reaction
Vessel which is performed using Siemens PLC.
In Level Control 4 Digital Inputs and 6 Digital Outputs are used. So ,
taking a prototype of Level Control, I try to use PLC to automate the
process.
Initially, the Liquid-1 is filled into Tank/Vessel using a pump via Inlet
valve-1. There are 3 levels namely Low, Medium, High. When Low and
Medium levels are reached Inlet valve-1 stops and Inlet valve-2 supplies
Liquid-2 until the High Level is reached.
Then Motor mixes both the Liquids for the specified time, the mixture is
drained out through Outlet valve.
Timing is to be maintained for running of Motor. Considering the PLC,
digital input is taken from limit switch.
The programming can be done by using various Simulation softwares
like
VERSAMAX
SIMATIC S7 etc.
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Wills Cutter
Market
Paper Machines Finishing HouseRewinders Cutters Sales Godown
Stock Preparation
Bleached Pulp
StoragePulp Drying Plant
Bleaching
(CD + EOP +D)
Chlorine Dioxide
Plant
Unbleached Pulp
Storage
Process Plants
DG Set Grid Power
Oxygen
Generation Plant
Washing /Screening
Oxygen
Delignification Power distribution for
Process & Colony
Evaporator
Digestor
ChemicalRecovery Boiler
Causticizing Plant
Turbo Generator
Set
Coal Fired
Boilers
Coal Handling
Plant
Chipper HouseRaw materials
Mixed Hard Wood
& Bamboo
Coating
Plant Rewinders Cutters
JK PAPER MILLS PROCESS FLOW DIAGRAMDust
White Liquor
Weak
Black
Liquor
Steam
Steam
Steam
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SMELT
Pulp to Paper
Process
BAMBOO
&
WOOD
RECOVERY
BOILER
EVAPORATOR
G/L
W W L
RECAUSTICIZINGAREA
STEAM
STEAM
STEAM
WBL :16-18%
CBL :55%-65%
WHITE LIQUOR
LIME
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INTRODUCTI
ON
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BMS stands for BURNER MANAGEMENT SYSTEM.
It is a part of Liquor Fired Boiler in Soda RecoverySection.
The problem of operation and safety posed by a Recovery
Boiler is much more than a conventional utility/Industrial
Boiler.
It is basically a chemical recovery process unit where the
organic material in the black liquor is burnt, while the
sodium salt is reduced and drained as molten smelt from
the furnace bottom. At the same time, the heat released is
utilized for steam generation.
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Though predominantly the heat for the process is obtained from
the burning of the black liquor, supplementary heat from oil
fired auxiliary fuel burners is required to start up the unit,
regulate the char bed , avoid blackouts and to augment
additional steam.
Here we are using PLC Programming and developed LadderLogic for Inputs and Outputs. The inputs and Outputs are
Digital ones.
The PLC used for BMS is HONEYWELL 620-35 PLC.Software used is 620 WINLOADER Version 5.4 .
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PULP
MILL
WBL
STORAGE
TANKS
EVAPORATORS
CBL
STORAGE TANKS
PUMP
60-65 DEG.C
SALT
CAKE
MIXING TANK
ESP ASH TANK
Na2SO4
INDIRECT
HEATER
102 DEG.C
HBLSECONDARY
HEATER
112 DEG.C
FURNACE
118 DEG.C
MUD
DISSOLVERTANK
87-95 DEG.C
ESP
DUST
SMELT
FLUE GAS
CAUSTICIZING
PLANT
G/L
W W L
ID
FAN
FLUE GAS
TO CHIMNEY
THICKBLACK LIQUOR
WHITE
LIQUOR
LIQUOR FIRED BOILER
SUPER HEATERSATURATED STEAM
SUPER HEATED/ DRY STEAM to TURBINE
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BMS SECTION
SATURATED STEAM
HAMMERS
ESPPLATES
FEED WATERPUMP
FLUE
GAS
MUDDRUM
FIRING
ZONE
STEAM
DRUM
SA /TA
FA
NDAYOIL
TANK
pump
S
TE
A
M
PA
FA
N
SCMT
HBL
pump
S
T
EA
M
IGNITOR
ESP ASH
TANK
DUST
IDFAN
FLUEGAS
FLUEGAS
SMELT
SUPER HEATER
SUPER HEATED/ DRY STEAM to TURBINE
ECONOMIZERSSPOUT
TANK
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THEORYof
BMS
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FEATURES
The BMS provides for the proper sequencing of equipment
during the normal startup operating and shut down procedures
and provides for an Auxiliary fuel trip and/or an Alarm during
an adverse burner or unit operating condition.
This is accomplished through the use of pre-wired logic and
various Interlocks.
The BMS is a local-manual relay system.
Starting burners are started and stopped locally from their
associated local switch boxes while the various header trip
valves are opened and closed remotely from associated Push
Buttons on BOILER CONTROL DESK(BCD).
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SCAVENG
E
V/V
OPENED
SCAVENG
E
V/V
CLOSED
FLAME
SCANNER
SHOWS FLAME
FLAME SCANNER
SHOWS NOFLAME
BURNE
R ON
BURNE
ROFF
HEA
IGNITORADVANCED
HEA
IGNITORRETRACTE
D
ATOMISIN
GV/V
OPENED
ATOMISING
V/VCLOSED
OIL GUN
ENGAGED
BURNER
V/VOPENED
BURNER
V/VCLOSED
BURNER
1
SCAVENGE
V/VOPENED
SCAVENGE
V/VCLOSED
FLAMESCANNER
SHOWS FLAME
FLAME SCANNER
SHOWS NO
FLAME
BURNER ON
BURNER
OFF
HEAIGNITOR
ADVANCED
HEAIGNITOR
RETRACTE
D
ATOMISING
V/VOPENED
ATOMISINGV/V
CLOSED
OIL GUNENGAGE
D
BURNER
V/V
OPENED
BURNER
V/VCLOSED
BURNER
2
SCAVENG
E
V/V
OPENED
SCAVENGE
V/V
CLOSED
FLAME
SCANNER
SHOWS FLAME
FLAME SCANNER
SHOWS NO
FLAME
BURNER ON
BURNER
OFF
HEAIGNITOR
ADVANCED
HEA
IGNITOR
RETRACTE
D
ATOMISIN
G
V/V
OPENED
ATOMISING
V/VCLOSED
OIL GUN
ENGAGED
BURNER
V/V
OPENED
BURNER
V/V
CLOSED
BURNER
4
SCAVENG
EV/V
OPENED
SCAVENG
EV/V
CLOSED
FLAME
SCANNERSHOWS FLAME
FLAME SCANNER
SHOWS NOFLAME
BURNER ON
BURNE
R
OFF
HEAIGNITOR
ADVANCED
HEAIGNITOR
RETRACTED
ATOMISIN
G
V/V
OPENED
ATOMISING
V/VCLOSED
OIL GUN
ENGAGED
BURNER
V/VOPENED
BURNER
V/VCLOSED
BURNER
3
BMS PANEL
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CLOS
E
HORV
BOILER
EMERGENCY
TRIP
SA/TA
FAN
STAR
T
PERM
IT
BLACK
LIQUOR
PUMP
START
PERMIT
ID FAN
RUNNING
SA/TA
FAN
RUNNIN
G
PURGE
READY
START
PURGE
PUSH
BUTTON
EMERGENCY
DRAIN & TRIP
PURGE
IN
PROGRESS
PURGE
COMPL
ETE
ALLEMERGEN
CY DRAINV/V S
CLOSED
ATOMIS
ING
STEAM
PRESS
URE
LOW
ATOMISI
NG
STEAM
PRESSU
RE HIGH
IDFAN
START
PER
MIT
PA FAN
START
PERMI
T
HO
PRESS
URE
LOW
HO
TEMPERATUR
E
LOW
PRECIPITA
TOROUTLET
TEMP.
>270
DEG.C
PRECIPITAT
OR
OUTLET
TEMP.
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FUNCTION
The following operations of the function are achieved in the
BMS.
Boiler purge.
Main oil header trip valve open/close operation.
Ignitor oil header trip valve open/close operation.
Auxiliary fuel burner ignitor ON/OFF operation.
Ignitor Flame scanning.
Auxiliary fuel burner start/stop operation.
Auxiliary fuel trip production. Emergency drain trip protection.
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FURNACE PURGE
Before any auxiliary fuel can be introduced in the unit(initial
or after an auxiliary fuel trip)a satisfactory furnace purge cyclemust first be completed. To start a furnace purge cycle,
proceed as follows:
Establish an (I.D. Fan Start,Permissive)by completing all of
the following conditions. *1A. All Emergency drain valves are closed.
*1B. Main oil header trip valve and ignitor trip valve closed.
*1C. Feed Water shut off valve is open.
1D. Evaporator outlet temperature less than 525oF.
1E. Precipitator outlet temperature less than 525oF.
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(*) Conditions preceded by an asterish are not required once
the ID fan is running.
2. Place I.D. Fan in service.
3. Place the Fans in service.
4. Adjust the primary air flow to maintain a minimum of 30%
of full load air flow.
5. See that all of the starting and all of the load carrying burnervalves are fully closed.
6. Reset the boiler trip by depressing the BOILER TRIP
RESET Push Button.
7. When the purge ready light comes on indicating that all ofthe purge requirements have been completed depress the
PURGE START PUSH BUTTON.
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TRIP VALVE
OPERATIONMAIN OIL HEADER TRIP VALVE: Depressing the main oil header trip valve open push button
once the furnace purge is completed, will open the main oil
header trip valve.
If the trip valve fails to open, check to see that,
All burner valves closed.
No auxiliary fuel trip exists.
As the trip valve moves from fully closed position the Main
Oil Header trip valve Open light comes on. When the tripvalve has been fully opened, the main oil header trip valve
closed light goes out. Once the trip valve is fully open, it will
be in OPEN position.
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OILHORV3 WAY
V/V
PRESSURE
CONTROL V/V
8.0 Kg/cm2
HOTVPRESSURE
CONTROL V/V
15.0 Kg/cm2
FURNACE OIL
FURNACE
HEATER
DAY
OIL
TANK
SCAVENGE V/V
HOBV
STEAM
PUMP
OIL BURNER VALVE
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AUXILIARY FUEL TRIP Any one of the conditions below will cause an auxiliary fuel
trip to occur,and results in the immediate shutdown of all of
the auxiliary fuel in service and necessitates completion ofanother furnace purge cycle before any auxiliary fuel firing
may be reinstated.
Evaporator outlet temperature greater than 525oF.
Precipitator outlet temperature greater than 525oF. I.D. Fan not in service.
Fans not in service.
Primary Air Flow less than 30% of full load of flow.
Furnace pressure greater than +4W.G.
Ignitor oil pressure not within controlled limits.(75% to 125%
of full load pressure).
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Ignitor air pressure greater than 75% of full load pressure.
Main oil pressure below 75% of full load pressure .
Starting burner oil header pressure above 125% of full loadpressure.
Load carrying burner oil pressure above 125% of full load
pressure.
Recirculation selector switch not in OPERATE position. A Boiler trip condition exists.
Either of the local auxiliary fuel trip push button depressed.
Both of the auxiliary fuel trip push buttons on the BCD
depressed.
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FURNACE
FLOW
METER
INDIRECT
HEATER
DIRECT
HEATER
112 DEG.C 118 DEG.C
HBLPUMP
PRESSURE
CONTROL
V/V
102 DEG.CHBL
ASHPUMP
ESP ASHTANK
LEVELCONTROL
V/V
CBL
TANK
CBL
UMP
ESP
ASH
TANK
ESP DUST
ESP
SCMT
Na2SO4
SALT CAKE
LIQUOR SPRAY GUN
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EMERGENCY DRAIN AND TRIP
An emergency drain and trip procedure is initiated if water in
any amount is known to be entering the furnace and cannot bestopped immediately or if any leaks external to the furnace
such as failure of gaskets, gage glasses etc.
An emergency drain is initiated by simultaneously depressing
the two Emergency Drain push button on the BCD panel. An emergency drain trip initiates the following.
*1. Auxiliary fuel trip.
*2. Fan trip.
3. Closing of the feed water valve.
4. Opening of the emergency drain valve.
* Conditions preceded by an asterisk are the same trip
inputs .
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BOILER TRIP A boiler trip condition exists when both the boiler trip
push buttons on the BCD pane are depressed or whenemergency drain is initiated. A boiler trip initiates thefollowing.
a. Auxiliary fuel trip.
b. P.A,S.A/T.A Fan trip.
c. Black liquor pump trip.
Depressing the two emergency drain push buttons results in an
instantaneous boiler trip. The feed water supply valve will not close,
however, until the following conditions are also satisfied.
All trip valves closed OR
Ignitor trip valve closed and All oil scanner valves closed.
The emergency drain valves should not open until the feed-water
valve is closed (This is an externally interlocked circuit).
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Alarms
The following alarm conditions will cause an annunciator alarm
to sound if the appropriate terminals on the BCD panel are
connected to the customers annunciators. The contacts are
normally open for the alarm conditions.
Furnace pressure greater than +4W.G.
Air flow less than 30%.
Ignitor oil pressure less than 75%.
Ignitor air pressure less than 75%.
Main oil pressure less than 75%.
Starting Burner Oil pressure greater than 125%.
Boiler trip.
Auxiliary fuel trip.
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I.D. Fan not running.
Fans not running.
Precipitator outlet temperature greater than 525oF. Feedwater shut off valve not open.
Emergency drain valves not closed.
Evaporator outlet temperature greater than 525oF.
Emergency drain and trip.
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ECONOMIZER: In boilers, economizers are heat exchange devices that heat
fluids, usually water, up to but not normally beyond theboiling point of that fluid.
Economizers are so named because they can make use of the
enthalpy in fluid streams that are hot, but not hot enough to be
used in a boiler, thereby recovering more useful enthalpy andimproving the boiler's efficiency. They are a device fitted to a
boiler which saves energy by using the exhaust gases from the
boiler to preheat the cold water used to fill it (thefeed water).
http://en.wikipedia.org/wiki/Boilinghttp://en.wikipedia.org/wiki/Enthalpyhttp://en.wikipedia.org/wiki/Boiler_feedwaterhttp://en.wikipedia.org/wiki/Boiler_feedwaterhttp://en.wikipedia.org/wiki/Boiler_feedwaterhttp://en.wikipedia.org/wiki/Enthalpyhttp://en.wikipedia.org/wiki/Boiling8/7/2019 AUTOMATION OF BMS SYSTEM OF BOILER USING PLC LADDER LOGIC
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PLC used in BMS
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PLC used is TATA HONEYWELL.
CPU : IPC 620-35.
SOFTWARE : 620 WINLOADER,VERSION 5.4
DC POWER SUPPLY
DIS : 26, DOS : 25.
INPUT : 110V/220V or 240V,5.5A Max.
OUTPUT : 25V DC,20A.
FREQUENCY : 50 HZ.
PLC SPECIFICATIONS :-
32K EXPANDABLE MEMORY. PLC used is a Redundant System.
I/O Handling Capacity : 2048 Real IOs.
Scan Rate : 50msec.
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The PLC used for BMS is HONEYWELL 620-35 PLC. Software used is 620
WINLOADER Version 5.4 .
PLC consists of 5 Modules:
1) Memory module
2) Register module
3) System Control module
4) Processor module
5) I/O Control module.
The PLC is Redundant type.
Redundant system has Running mode and Standby modeslots.
If Running mode wont work then Standby mode is used byPLC for functioning.
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A Key is present in the PLC.
It has four modes:
1.Program
2.Disable
3.Run/Prog.
4.Run
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LADDER LOGICS
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3066
112 3065 2301 2302 2303 3043 160 368 557
NO BOILERTRIP
AUXILLIARYFUEL TRIP
HOTVCLOSED
AUXILLIARYFUEL TRIP
PURGECOMPLETE
PURGEREADY
The Condition for Purge Ready is satisfied when Boiler is in healthy
condition, AFT occurs due to pressure difference. Other interlocks are
Header Oil v/v should be closed and Purge Complete is kept active
low.
ID FANSA/TA FAN FURNACE ID FANAIR FLOW DRUM LEVEL
PA FAN FURNACE DRUM LEVEL
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ID FAN
START
PERMIT
SA/TA FAN
RUNNING
FURNACE
PRESSURE
VERY HIGH
ID FAN
RUNNING
AIR FLOW
>30%DRUM LEVEL
VERY LOWPA FAN
RUNNING
FURNACE
PRESSURE
VERY LOW
DRUM LEVEL
VERY HIGH
30493051 30533048 3032 3033 3050 2301115 3052
The output coil 2301 is a flag and it is Energized when
Secondary/Tertiary Fan shall be running that supplies Air flow >30% to Upper layer of Furnace, Primary Fan should also run that
supplies Air to Lower layer of Furnace.
The Furnace Pressure and Drum level should be low and ID Fan
should start running for flue gas to be sent out.
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B-1 SCANNER
SHOW FILM
B-2 SCANNER
SHOW FILM
B-3 SCANNER
SHOW FILM
B-4 SCANNER
SHOW FILM
B1-4 SCANNER
SHOW FILM
230230233002 3007 3018
The Scanner Film is present at Furnace through which the level, floware monitored. So, the I/Ps should remain active low.
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B-1 HOBV
CLOSED
B-2 HOBV
CLOSED
B-3 HOBV
CLOSED
B-4 HOBV
CLOSED
B1-4 HOBV
CLOSED
230330223001 3006 3017
During Purge Ready initially the Furnace is Purged with fresh Air. So,the Header Oil Burner v/vs B1-B4 should be closed.
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INDUSTRIAL SPECIFICATIONS
FURNACE TEMP. : 600deg.C(inlet),650deg.C
FURNACE STEAM: 35TPH
ECONOMISER TEMP. :
380deg.C(inlet) , 160deg.C(outlet)
ESP TEMP. : 160deg.C(inlet),150deg.C(outlet)
STEAM DRUM WATER LEVEL : 54% SUPER HEATED STEAM TEMP. : +/- 410 deg.C
CHIMNEY TEMP. : 140 - 150 deg.C
GREEN LIQUOR OUTLET : 1000 TPH/DAY
STEAM PRESSURE O/L : 36kg/cm2
STEAM TEMP. O/L : 410 415 deg.C
STEAM FLOW O/L : 36 TPH.
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IMPLEMENTATION
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Level Control in a Reaction Vessel
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PLC used in
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PLC used inLEVEL CONTROL
PLC WIRING
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PLC WIRINGDIAGRAM
The SIEMENS PLC specifications used for Level Control are :
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pSoftware : STEP 7 LITE.MODEL : S7 30016 Digital Inputs
4 Analog Inputs16 Digital Outputs9 Relay Outputs2 Analog Outputs
Q1 : 24 V DC 0.5A MAXThe Inputs and Outputs used in this project are Digital I/O s only.
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EXPLANATION:
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In Rung-1 the Switch I0.0 is active high and remaining I/Ps are kept active low. The
O/Ps of v/v-1 and Pump-1 shall be active high (Q0.0 & Q0.4), a latch of O/P v/v-1is
given to I0.1 because if Chemical-1crosses I0.1 then I0.1 will become active high and
O/Ps shall become active low. So, latch is provided for O/Ps to remain active high.In Rung-2 I0.0, I0.1 & I0.2 shall remain active high and O/Psof v/v-2 and Pump-2
shall be active high (Q0.1 Q0.4) as Chemical-1reaches Medium level, at same instant
Chemical-2 shall flow to the vessel and Chemical-1 cease to flow.In Rung-3 as Chemical-2 reaches I0.3 Chemical-2 cease to flow, when I0.3 is active
high then memory O/P of MotorM0.1 is set as M3.1,latch ofM0.1 make Motor to run
continuously .In Rung-4 I0.0,M0.1are kept active low and O/P of TimerM0.5,memory O/P of Drain
v/v M3.2 are active low. When M0.5 becomes high Motor stops.In Rung-5 M0.1acts asI/P to ON-Delay Timer, when Timer is activated Agitator
mixes both Chemicals.M0.5 shall be On after 10 seconds Delay.
In Rung-6 M0.5 shall be active high making Drain v/v Q0.6 to open with thecondition I0.1be active high.M3.2 is set memory of Drain v/v Q0.6 .Finally in Rung-7 when processed Chemical falls below I0.1 Drain v/v closes and this
process continues until Start/Stop Switch is pressed.In Rung-8 memory M3.3 &M3.4 are given to M3.1 to become reset because if motor
stops in middle then manually processed Chemical is drained , if power comes thenmotor resets.
WORKING :
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WORKING :
Initially the Tank shall be Empty.
When the Start Push Button is pressed the Pump-1 and Inlet v/v-1willbe ON i.e., Chemical-1 shall flow from Pump-1 to Tank.Chemical-1 reaches Minimum/Low Level then it reaches Medium
Level.As the Mid Level is reached Chemical-1 stops flowing from Pump-1
and Chemical-2 is supplied by Pump-2 via Inlet v/v-2.When Maximum/High Level is reached by Chemical -2 ,Pump-2 cease
to supply Chemical-2.Then Motor shall be ON for specified time for mixing of both the
Chemicals with Agitator that is connected to Motor.When Motor Stops the Outlet v/v will drain the processed Chemical
mixture Outside.This process continues until Stop Push Button is pressed.
APPLICATIONS
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APPLICATIONS :
Used in Bottling plants.Used in Chemical Industries like Fertilizers, Drugs.
Used in Paper, Cement Industries .
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Conclusion:-
The main theme of this Study project is Purging theFurnace at initial stage and activating the Emergency Trip
and Drain valves during abnormal conditions while
continuous running of process.
This project can be used for better functioning of Boiler
plant without any malfunctions by continuously
monitoring the Industrial parameters and protecting the
Boiler from destruction. PLC requires hardwiring only once and if there
is any change in wiring , we can easily changeit.
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Recovery department
Power block department
INSTRUMENTATION department
JKPM Management
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Authorised By
SANTOSH BHARADWAJ REDDYEmail: help@matlabcodes.comEngineeringpapers.blogspot.comMore Papers and Presentations available on abov
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