Project Report on

BOILER DRUM LEVEL CONTROL USING PLC

Submitted in partial fulfilment of The requirements for the degree of

(2012-13)

BACHELOR OF TECHNOLOGY IN INSTRUMENTATION AND CONTROL

By

GOWARDHAN AGRAWAL(110909028) HARER RAKESH(110909006) PANKE ANKIT(110909015) KALWAGHE PANKAJ(110909020) UNDER THE GUIDANCE OF SAPANA KORDE

Department of Instrumentation and Control College of Engineering Pune-411005 (2012-13)

ACCEPTANCE CERTIFICATE Department of Instrumentation and Control College of Engineering Pune

(An autonomous Institute of Government of Maharashtra)

The project entitled Title of the project submitted by Agrawal Gowardhan, Harer Rakesh, Panke Ankit, Kawaghe Pankaj having MIS No 110909028, 110909006, 110909015, 110909020 respectively accepted for being evaluated.

Prof. Sapana Korde Project Guide Date:-

Head of Department Instrumentation and Control Date:-

PROJECT APPROVAL CERTIFICATE Department of Instrumentation and Control College of Engineering Pune
(An autonomous Institute of Government of Maharashtra)

The project entitled Title of the project submitted by Agrawal Gowardhan, Harer Rakesh, Panke Ankit, Kawaghe Pankaj having MIS No 110909028, 110909006, 110909015, 110909020 respectively is approved for the degree of Bachelor of Technology in Instrumentation and Control.

Prof. Project Guide

Head Department of Instrumentation and Control

Examiner

Date:-

Contents
Acceptance Certificate..I Approval Certificate..II Abstract.III List of Figures ..IV

Chapter 1 Introduction1 1.1 Background Information and Research7 1.2 Hypothesis8 1.2.1 General Block Diagram Of Boiler Drum 1.2.2Feed water Control 1.2.3 Boiler efficiency 1.2.4 Automated Boiler Controls and Systems 1.3 Block Diagram..10 1.4 Process Description......10

Chapter 2 2.1 2.2 Chapter 3 3.1 Boiler Level Control Strategies.14 3.1.1 Single-Element Control 3.1.2 Double-Element Control 3.1.3 Three-Element Control The Boiler Water/Steam Drum..11 The Effect of Feed water Temperature on Boiler Performance.12

3.2 Drawback of conventional system..18 3.3 Flow chart for boiler drum level control..19 3.4 Critical Control Parameters in Boiler...20

Chapter 4 4.1 Programmable Logic Controller..21 4.2 How PLC works22 4.3 PLC Working.24 4.4 Connecting to the PLC. 25

Chapter 5 5.1 Boiler Operation..26 5.2 PID Controller.27 5.3 Ziegler-Nichols closed-loop tuning method28 5.4 SCADA...30

Abstract
In the industrial sector esp. power plants, the demand for high quality, efficiency and automated machines is increasing. Power plant units need to be closely monitored and supervised on a regular basis. In this Project the focus is on automating the boiler which is a crucial component of the power plant. If we are going for automation it is also necessary to design a system that monitors the system and minimizes human errors. The system used here is SCADA-Supervisory Control and Data Acquisition which monitors and PLC (Programmable logic controller) that is used for internal instruction storage and implementation of functions such as sequencing, timing etc. to control via digital I/O modules of various types of machine processes. PLC applications are extensively used in industry to control and facilitate repetitive processes such as manufacturing cell management, fly-by-wire control, or nuclear plant shutdown systems. One of these applications is industrial automation which includes numerous automated processes. This again includes automation of boiler which demands determination of certain physical parameters (viz. pressure, temperature, etc.) & utilizing these parameters to make the boiler start-stop or function in any manner we want, but automatically.

List of Figures
Fig:1.1 Block diagram for boiler Fig:1.2 P&ID diagram for boiler Fig:2.1 Block diagram of boiler Fig:3.1 one-Element Control, of boiler Fig:3.2 two-Element Control, of boiler Fig:3.3 three-Element Control, of boiler Fig:3.4 flow chart for boiler drum level control Fig. 4.1 I/O Pin Configuration of AB PLC Fig:4.2 interfacing in PLC Fig:4.3 interaction with PLC (a) & (b) Fig:4.4 Tuning parameters Fig:5.1 PID Controller block diagram Fig:5.2 System tuned using the Ziegler-Nichols closed-loop tuning method Fig:5.3 SCADA Screen result

Chapter 1 Introduction
1.1
1.1.1

Background Information and Research

Literature Review
At the centre of nearly all power stations is a generator, a rotating

machine that converts mechanical energy into electrical energy by creating relative motion between a magnetic field and a conductor. The energy source harnessed to turn the generator varies widely. It depends chiefly on what fuels are easily available and the types of technology that the power company has access to. A power station is a facility for the generation of electric power. 'Power plant' is also used to refer to the engine in ships, aircraft and other large vehicles. Some prefer to use the term energy centre because it more accurately describes what the plants do, which is the conversion of other forms of energy, like chemical energy, gravitational potential energy or heat energy into electrical energy. However, power plant is the most common term in the India, while elsewhere power station and power plant are both widely used. The Boiler Management Control System shall incorporate a microprocessor based design and provide the operating control function of the boiler system and modulation control of fuel and combustion air as well as the firing rate motor to meet system demand. Over the years the demand for high quality, greater efficiency and automated machines has increased in the industrial sector of power plants. Power plants require continuous monitoring and inspection at frequent intervals. There are possibilities of errors at measuring and various stages involved with human workers and also the lack of few features of microcontrollers. Thus a sincere attempt is here to explain the advantages the automation into them. The boiler control which is the most important part of any power plant, and its automation is the precise effort.

1.2

Hypothesis

1.2.1 General Block Diagram Of Boiler Drum

The block diagram of boiler control is shown in above figure the output from the boiler i.e. the steam outputs and the level of water is given to transmitters. The output of transmitter is given to the controller which act as level indicator controller and flow indicator controller. If there is any error corresponding to desired set point, the signal from controller is given to the converter which will open or close the valve and the water will be drained out or filled according to required steam. The major loops in boiler control are: 1) Combustion control 2) Feed water control

Fig:1.1 Block diagram for boiler

1.2.2 Feed water Control

Feed water control is the regulation of water to the boiler drum. It provide a mass accounting system for steam leading and feed water entering the boiler. Proper boiler operation requires that the level of water in the steam drum should be maintained within certain band. A decrease in this level may uncover boiler tubes, allowing them to become overheated. An increase in the level of water may interfere with the internal operation of internal devices in the boiler drum. It is important to made that the water level in the boiler drum must be above 50% all the time. As system for feed water control must be designed to maintain the mass balance over expected boiler load changes so that the level in the steam drum remains within the required limits for safe and efficient operation. Control system complexity is based on number of measured variables used to initiate control action and include single element ,two

element,3 element and advanced control schemes to improve accuracy of final control action.

1.2.3 Boiler efficiency

It simply defined as the amount of energy in the stem or hot water leaving the boiler minus the energy in the feed water divided by the amount of energy in the fuel used. Boiler efficiency = (Eout Efw)/Efuel Eout : amount of energy in the stem or hot water Efw : amount of energy in feed water Efuel : amount of energy in fuel Boiler efficiency must always be less than combustion efficiency. Typical boiler efficiency is 75% to 85%.The various goals of boiler control includes: 1. To minimize excess air2. To minimize blow down3. To minimize steam pressure4. To measure efficiency

1.2.4 Automated Boiler Controls and Systems

Heat recovery systems Level controls Boiler TDS control system Condensate contamination detection systems Automatic boiler Blow down system

1.3

Block Diagram

Fig:1.2 P&ID diagram for boiler

1.4 Process Description

Input flow of water is given by positive displacement pump. Heating of water in boiler is done by electric heater. During heating process we monitor pressure, temperature of drum by temperature and pressure sensors. Before we start motor level of drum should be checked and that is done by differential pressure transmitter if drum level is below low level then heater runs in dry mode so level is critical parameter for boiler drum safety. Super saturated steam temperature is measured using RTD which is mounted in the line and on the top of line. Vortex flow meter is used to measure flow of steam. Using globe type valve we control flow of steam then steam is fed to the heat exchanger where we apply load of cold water. Cold water fed to the heat exchanger from cold tank with the help of centrifugal pump. Flow of cold water is measured using magnetic flow meter.

Chapter 2
2.1 The Boiler Water/Steam Drum control
The boiler water/steam drum, or steam drum, is an integral part of the boilers design. This vessel has three specific purposes; 1] provide a volume space to hold the boiling water in the boiler, 2] provide enough water volume to allow for good thermal mixing of the cooler bottom drum water with the hotter surface interface water, and 3] provide surface area and volume for the efficient release of the entrained steam bubbles from the boiler water. The surface area and volume of the vapor space in the water/steam drum is critical to the efficient separation of the steam bubbles from the water. Too small an area can result in an excessive surface tension and high velocities, which result in wasted heat and drum water carry-over. Too large an area is simply a waste of materials and labor to construct the vessel. The boiler water/steam drum also provides a logical location for 1] addition of feed water, 2] addition of chemical water treatment and 3] surface blow down, which helps reduce the surface tension of the water/

Fig:2.1 Block diagram of boiler

High water levels raise steam exit velocities and result in priming or boiler water carryover in to the distribution system. Priming results in wet dirty steam while carry-over can result in dangerous water hammer and pipe or equipment damage.

2.2 The Effect of Feed water Temperature on Boiler Performance

It is the influence of feed water temperature on packaged boilers, which is most commonly overlooked when selecting a feed water strategy. If we acknowledge that boilers are rated from and at feed water temperatures of 212 degrees F and zero PSIG, then the choice between ON/OFF feed water control or Modulating feed water control becomes of great importance as boiler horsepower, volumes and load swings increase. To gain operating pressure in the boiler drum additional Btu input is required to raise the water temperature from the threshold of 212 degrees F steaming temperature to that of operating pressure. The steam tables and the chart below help to expand on this.

ON/OFF feed water control introduces sudden volumes of sub-cooled water at twice the boilers steaming capacity, which results in large excursions in the boiler water temperature, drum level and drum pressure. These excursions reduce boiler performance and fuel to steam efficiency by sub-cooling the boiler feed water and requiring the burner to over-fire to compensate for the sudden mass/heat upset. While this may be acceptable in small boiler applications, it can become both inconvenient and dangerous in larger boilers. As an example a 500 Bhp (17,250 PPH) (287 PPM) boiler is operating at 225 PSIG with a boiler water temperature of 397 degrees F. The boiler is operating at 75% firing rate and 80 percent efficiency producing 12,900 PPH (215 PPM) steam flow (15,686,720 Btu Input). The feed water system is ON/OFF and has a recovery volume of 3% low water capacity (517.5 Lbs.) at the call for water switch point and a 2% over capacity (345 Lbs.) at a stop water switch point for a total of 5% water recovery capacity. This is 862.5 pounds of water. At the current steaming rate the feed water cycle is 4.01 minutes (862.5/215). The feed water pump in this application would be capable of delivering 575 pounds of water per minute, i.e. twice the maximum steaming rate. Feed water temperature is 180 degrees F as it is assumed no deaerator or economizer is being used since neither of these components can function in an ON/OFF feed water system.

The cylindrical vessel where the water-steam interface occurs is called the boiler drum. Boiler drum level is a critical variable in the safe operation of a boiler. A low drum level risks uncovering the water tubes and exposing them to heat stress and damage. High drum level risks water carryover into the steam header and exposing steam turbines to corrosion and damage. Drum level control is complicated by the inverse response in level to a change in the firing rate. This phenomenon is known as swell and shrink. When the firing rate increases, vapor bubbles form at a faster rate and that causes the drum level to rise or swell. A decrease in firing rate causes drum level to shrink. The problem associated with the swell and shrink phenomenon is that a standard feedback control loop measuring level cannot correct for load changes without wide swings in drum level. When drum level swells, feed water flow decreases in order to correct for level. However, feed water should be increasing in order to match the higher steam demand. The level control loop does not start to correct for the increase in steam flow until after drum level has fallen below set point. The risk is that drum level can significantly drop before the control system finally adjusts to the change in steam load.

Drum Pressure [1E, 2E and 3E] Since the density of steam and water at the saturation temperature change with pressure, the drum level calibration will only be accurate at a single boiler drum pressure. The drum level signal can be compensated for all pressures by using a drum pressure transmitter. Pressure compensation is typically employed with utility boilers that operate at much higher pressures than industrial boilers, but this strategy is useful for either application. Steam Flow [2E and 3E] Steam flow is a mass flow measurement typically in kpph (thousand pounds per hour). This measurement can be made using a differential pressure transmitter across an orifice plate, venturi meter, or nozzle. In order to calculate mass flow, steam density compensation is required. With saturated steam, density can be determined by measuring the upstream static pressure.

Chapter 3
3.1 Boiler Level Control Strategies
Modulating control of the water/steam interface level is normally addressed in one of three principal strategies, single-element, two-element or three-element control. The application of any one of these strategies depends on the specific boiler size (economics) and load variations (dynamics).

3.1.1 Single-Element Control

Single-Element control is perhaps the simplest strategy. In this system drum level is measured using a single measurement device and provides a control signal to the feed water regulator in direct relation to the current operating drum level. This system is used in both ON/OFF and modulating feed water control strategies. The single-element drum level strategy is only effective for smaller boilers with relatively steady demands and slow to very moderate load changes. This is because the shrink and swell effect causes an incorrect initial control reaction, which can lead to over/under filling of the drum. (See ON/OFF control example above.) As steam demand increases, there is an initial lowering of the drum pressure resulting in an artificial rise in drum level as the steam bubbles expand and swell the drum water level. This phenomenon sends a false control signal to reduce feed water flow, when in fact the feed water flow should be increasing to maintain mass balance. Conversely, on a loss of steam demand, there is an initial rising of steam drum pressure which acts to lower the drum level by compressing the steam bubbles and shrinking the drum water level. This sends a false signal to increase feed water flow when in fact it should be decreasing to maintain mass balance.

Fig:3.1 one-Element Control, of boiler

Processes experiencing sudden or large load changes, can result in phasing of the shrink and swell effect causing the water level controller to lose control of the drum level and result in nuisance low water trips or high water priming and carry-over.

3.1.2 Two-Element Control

The two-element drum level strategy is suitable for processes with moderate load swings and speeds, and it can be used on any size of boiler. This system uses the two variables, drum level and steam flow to mass balance the feed water demand. Drum level is measured and the error between the desired set point and the actual control point is sent to a math summer as one of two process variables. Steam flow is measured and added (summed) to the math summer as the second process variable. The result of the math summer is the control output to the feed water control valve. Since steam flow is very dynamic, the result of this strategy is that it will sense the rise or fall in load demand before the drum level begins to change. The strategy then adds or

subtracts control output to stabilize the reaction of the drum level controller on the feed water control valve. And since steam flow is normally the larger variable it can easily over ride the trim effect of the drum level measurement on moderate load changes, insuring a correct response to the demand change. During steady load the drum level controller influences the feed water control valve and acts to trim the level to the desired set point

.
Fig:3.2 Two-Element Control, of boiler

This strategy has two drawbacks, which should be considered. First like the single element strategy the two-element control can not adjust for pressure or load

disturbances in the feed water supply, as this is not a measured variable in this strategy. And second the two-element control cannot eliminate phasing interaction between feed water flow and drum level because only the relatively slow process of the drum level is controlled. This second issue can lead to sub-cooled drum water on a large increase in demand by allowing excessive feed water to enter the drum without consideration to the boilers thermal dynamic capabilities.

3.1.3 Three-Element Drum Level Control

To address the issues of phasing still present in the two-element control strategy, a third element, feed water flow is added to the drum level control strategy. In this system the math summer output of the two-element controller is cascaded down to a second Feed water Flow Controller to act as a Remote Set point. The feed water controller is a fast acting flow controller, which uses feed water flow as its process variable and steam flow as its set point. Thus for every pound of steam flow leaving the boiler a pound of feed water is added. This loop has final control on the feed water valve. As the remote set point from the two element level control changes with steam flow and drum level variations due to blow down or other minor losses, the feed water controller modulates its output to regulate the necessary feed water flow to keep the drum level in a mass/heat balanced and level state. Independent tuning of each controller allows for very precise control of the drum level regardless of steam demand and feed water influences. However it is very important to take the thermal dynamics of the boilers recovery rate into account when tuning the feed water controller. If you fail to do this and set the controller reset too fast on the feed water controller you may inadvertently sub-cool the drum and start a cyclic phasing action much like that found in a two-element system. Do the math it will save you a lot of heartache. The three-element control strategy can easily handle large and rapid load changes because it is matching the mass balance between the steam flow from the boiler and the feed water flow to it. This strategy is a must on multiple boilers sharing the same feed water header and supply system, due to the variations in the available feed water flow to any one boiler, while two or more boilers are on line. This is irrespective to boiler size. Additionally if the boilers are subjected to sudden or unpredictable demand changes such

as in a batching process, this strategy is capable of matching these demands without operator trim corrections or supervision.

Fig:3.3 Three-Element Control, of boiler

3.2 Drawback of Conventional System

Conventional equipment systems are prone to errors due to the involvement of humans in the data collection and processing using complicated mathematical expressions. Thus what we require is a system that collects raw data, processes it and presents it in values which can be verified and compared with the standard values. In the coding process of this implementation with micro-controller, it requires a fast and efficient processing which on the other part depends on the length and sub-routines of the coding process. Thus it provides a real challenge with systems involving.

All the values can be filled up by the introduction of the automation technique into the power plants. The automation technique involving the automatic control of all the processes which includes the monitoring and inspection needs provides for a very efficient system. The automation process helps the company having the power plant to reduce the amount of errors that occur , reduction in the human resources, increased efficiency, and most importantly very cost effective.

3.3 Flow chart for boiler drum level control

Fig:3.4 flow chart for boiler drum level control

3.4 Critical Control Parameters in Boiler

Level Control - Steam Drum level, De-aerator level and hot well level

Pressure Control - Force draft pressure, Induced draft pressure, Steam drum pressure, Deaerator pressure, Turbine inlet steam pressure, balanced draft pressure Flow Control - Air flow, Steam flow, Water flow

Temperature Control - Deaerator temperature, Steam drum temperature, Underbed boiler temperature, Turbine inlet steam temperature, Flue gas temperature. Automation - Delegation of Human Control to technical Equipment aimed towards achieving. Advantages Higher productivity, Superior quality of end product, Efficient usage of raw materials and energy, Improved safety in working condition.

Manual Control In this, the Control and Automation are done by Manual Operations.

Drawbacks:

Human Errors subsequently affect quality of end product. Hard Wired Logic Control In this, Contractor and relays together with timers and counters were used in achieving desired level of automation. Bulky and complex wiring, Involves lot of rework to implement changes in control logic, the work can be started only when the takes is fully defined and this leads to longer project time.

Electronics Control with Logic Gates In this, Contactor and Relays together with timers and counters were replaced with logic gates and electronic timers in the control circuits.

Advantages Reduced space requirements, energy saving, less maintenance and hence greater reliability.

Chapter 4
4.1 Programmable Logic Controller
Programmable Logic Controller or PLC is an intelligent system of modules, which was introduced in the control, & instrumentation industry for replacing relay based logic [4]. Over a period of time, better I/O handling capabilities and more programming elements have been added along with improvement in communication

Fig. 4.1 I/O Pin Configuration of AB PLC

In this, instead of achieving desired control and automation through physical wiring of control devices, it is achieving through program say software.

Advantages Reduced Space, Energy saving, Modular Replacement, Easy trouble shooting, Error diagnostics programmer, Economical, Greater life and reliability, The Compatibilities of PLCS, Logic Control, PID control, Operator control, Signaling and listing, Coordination and communication.

4.2 How PLC works ?

Basics of a PLC function are continual scanning of a program. The scanning process involves three basic steps. Step 1: Testing input status First the PLC checks each of its input with intention to see which one has status on or off. In other words it checks whether a switch or a sensor etc., is activated or not. The information that the processor thus obtains through this step is stored in memory in order to be used in the following steps.

Fig:4.2 interfacing inPLC

Step 2: Programming execution Here a PLC executes a program instruction by instruction based on the program and based on the status of the input has obtained in the preceding step, and appropriate action is taken. The action might be activation of certain outputs and the results can be put off and stored in memory to be retrieved later in the following steps. Step 3: Checking and Correction of output status Finally, a PLC checks up output signals and adjust it has needed. Changes are performed based on the input status that had been read during the first step and based on the result of the program execution in step two following execution of step three PLC returns a beginning of the cycle and continually repeats these steps . Scanning time = Time for performing step 1+ Time for performing step 2+ Time for performing step 3.

4.3 PLC Working

At the beginning of each cycle the CPU brings in all the field input signals from the input signals from the module and store into internal memory as process of input signal. This internal memory of CPU is called as process input image (PII). User program (Application) will be available in CPU program memory. Once PII is read, CPU pointer moves in ladder program from left to right and from top to bottom. CPU takes status of input from PII and processes all the rungs in the user program. The result of user program scan is stored in the internal memory of CPU. This internal memory is called process output image or PIQ. At the end of the program run i.e., at the end of scanning cycle, the CPU transfers the signal states in the process image output to the output module and further to the field control. I/O driver (SCADA) picks up PII and PIQ and transfers the image to database and this image is called driver image. This driver image available in SCADA database is used for graphical view of process monitoring from operator station (OS) in the central control room.

Fig: (a)

Fig: (b)

Fig:4.3 interaction with PLC (a) & (b)

4.4 Connecting to the PLC

Open a SCADA application Create a tag of type I/O discrete, select the type as discrete Select read only if you dont want to force values to PLC. Selecting read and write allows to the SCADA to read and force values to the PLC. Type an access name. The access name can visualized as a gateway for a group of resources. Most of PLC drivers communicate with SCADA package using DDE, DDE requires three parameters namely name of the DDE server, topic name and item name. In case of reading a number of items from a particular PLC driver application name topic name are common, so this application name that is name of the DDE server and Topic name combine to form an access name. Access name is required to be defined only once then other items of driver can be accessed by using the Access name and item name. These details will be provided by the driver vendor or developer. Click ok, the access name will be listed finally click done, then type the item name, click save to save the I/O tags. Go to run time to communicate with PLC.

Fig:4.4 Tuning parameters

Chapter 5
5.1 BOILER OPERATION
Water plays a major part in the generation of steam. Inlet water to the steam drum should be in purified form, for that, PH value of the water should be maintained, and stored in deaerator tank. Feed water pump is switched ON by using feed water pump switch. The water from the de-aerator tank is allowed to pass through two parallel pipes. In one pump the flow rate is maintained at 130% and in another it is 5%. Thus the failure of any one pipe does not affect the boiler operation. The water is passed through economizer, thus the heat in the outgoing gases is recovered, by transferring its heat to the water. Then the heated water is made to flow through steam and water drum. In this, water should be maintained at least at 50%. For sensing water level we use PID controller in AB PLC. When the level is lesser than or greater than 50%, PID controller senses the level change and sends the appropriate control signal to the feed water valve 1 or valve 2. Thus, in spite of any changes in disturbance variable, the water level can be maintained at 50% by proper turning of PID controller. Water in the water drum is maintained at more than 75%. This water is circulated back to steam and water drum, due to difference in temperature, high amount of steam is generated. The generated steam temperature may be greater or lesser than the desired temperature. So depending on the situation the generated steam is then passed through primary heater followed by secondary heater. The secondary temperature is monitored. Here we consider three main cases: 1. If the secondary heated temperature is greater than the desired temperature then by using PID controller, approximate control signal is sent to the control valve 3 of the super heater tank, to reduce the temperature, by spraying chilled water from de-aerator tank. 2. If the output of the secondary heated temperature is lesser than the desired, using a PID controller approximate control signal is sent to bunker valve to control fuel flow. 3. If the output of the secondary heated temperature equals the desired temperature, no control action is needed, the stem is taken out.

5.2 PID Controller

A proportional-integral-derivative

controller (PID

controller)

is

generic control

loop feedback mechanism (controller) widely used in industrial control systems. A PID controller calculates an "error" value as the difference between a measured process variable and a desired set point. The controller attempts to minimize the error by adjusting the process control inputs. The PID controller calculation (algorithm) involves three separate constant parameters, and is accordingly sometimes called three-term control: the proportional,

the integral and derivative values, denoted P, I, and D. Heuristically, these values can be interpreted in terms of time: P depends on the present error, I on the accumulation of past errors, and D is a prediction of future errors, based on current rate of change.[1] The weighted sum of these three actions is used to adjust the process via a control element such as the position of a control valve, a damper, or the power supplied to a heating element. In the absence of knowledge of the underlying process, a PID controller has historically been considered to be the best controller.[2] By tuning the three parameters in the PID controller algorithm, the controller can provide control action designed for specific process requirements. The response of the controller can be described in terms of the responsiveness of the controller to an error, the degree to which the controller overshoots the set point and the degree of system oscillation. Note that the use of the PID algorithm for control does not guarantee optimal control of the system or system stability.

Fig:5.1 PID Controller block diagram

5.3 Ziegler-Nichols closed-loop tuning method

The Ziegler-Nichols closed-loop tuning method allows you to use the ultimate gain value, Ku, and the ultimate period of oscillation, Pu, to calculate Kc . It is a simple method of tuning PID controllers and can be refined to give better approximations of the controller. You can obtain the controller constants Kc , Ti , and Td in a system with feedback. The Ziegler-Nichols closed-loop tuning method is limited to tuning processes that cannot run in an open-loop environment.

Determining the ultimate gain value, Ku, is accomplished by finding the value of the proportional-only gain that causes the control loop to oscillate indefinitely at steady state. This means that the gains from the I and D controller are set to zero so that the influence of P can be determined. It tests the robustness of the Kc value so that it is optimized for the controller. Another important value associated with this proportional-only control tuning method is the ultimate period (Pu). The ultimate period is the time required to complete one full oscillation while the system is at steady state. These two parameters, Ku and Pu, are used to find the loop-tuning constants of the controller (P, PI, or PID). To find the values of these parameters, and to calculate the tuning constants, use the following procedure: Closed Loop (Feedback Loop) 1. Remove integral and derivative action. Set integral time (Ti) to 999 or its largest value and set the derivative controller (Td) to zero. 2. Create a small disturbance in the loop by changing the set point. Adjust the proportional, increasing and/or decreasing, the gain until the oscillations have constant amplitude. 3. Record the gain value (Ku) and period of oscillation (Pu).

Figure:5.2 System tuned using the Ziegler-Nichols closed-loop tuning method

4. Plug these values into the Ziegler-Nichols closed loop equations and determine the necessary settings for the controller.

Table 5.1 Closed-Loop Calculations of Kc, Ti, Td

Advantages 1. Easy experiment; only need to change the P controller 2. Includes dynamics of whole process, which gives a more accurate picture of how the system is behaving

5.4 SCADA(Supervisory control and data acquisition system)

SCADA stands for Supervisory Control and Data Acquisition. As the name indicates, it is not a full control system, but rather focuses on the supervisory level [2]. What is SCADA? It is used to monitor and control plant or equipment. The control may be automatic or initiated by operator commands. The data acquisition is accomplished firstly by the RTUs scanning the field inputs connected to the RTU (it may be also called a PLC

Fig:5.3 SCADA Screen result

programmable logic controller.). This is usually at a fast rate. The central host will scan the PTUs (usually at a slower rate). The data is processed to detect alarm conditions, and if an alarm is present, it will be displayed on special alarm lists. A. Basics A SCADA system consists of a number of components [7]. The RTUs. Remote telemetry or terminal units. The central SCADA master system. Field Instrumentation The SCADA RTU is a (hopefully) small ruggedized computer, which provides intelligence in the field, and allows the central SCADA master to communicate with the field instruments. It is a stand-alone data acquisition and control unit. Its function is to control process equipment at the remote site, acquire data from the equipment, and transfer the data back to the central SCADA system. FIX32 software enables you to configure a system environment that provides: [3] Supervisory control, batch processing, data acquisition, continuous control, and statistical process control for industrial applications.

References:
Rockwell Automation SCADA System Selection guide Allen-Bradley, Publication AG-2.1. Boyer, Stuart, A. SCADA: Supervisory Control and Data Acquisition, Instrument Society of America, Research Triangle, NC. 1993. Control of Boiler Operation using PLC SCADA - K. Gowri Shankar Instrumentation & Control Process Control Fundamentals

ACKNOWLEDGEMENT
We are taking this opportunity to express our sincere gratitude from the bottom of our hearts to our projects guide Prof. Sapana Korde for her valuable guidance and whole hearted cooperation. This project work was possible only because of her active support ,encouragement with timely valuable suggestion. We are thankful to madam whos continues suggestion , support and encouragement helped us in the satisfactory completion of this work and helped us to complete this project work.