N2 Unit - Cost Elimination

by In-House Logic
Development
A Presentation by Asadullah Qureshi/AQ (I&E ROP)

Current Arrangement at the N2 Unit

Nitrogen extraction at the N2 Unit is carried out using Siemens S7200 family of PLCs CPU 222 at the Old N2 Unit and CPU 224 at the
New N2 Unit.
However, the PLCs come pre-programmed and the program is
protected using a Level 4 Lock.
A Level 4 Lock means the program cannot be accessed for either
modification or back-up purposes.

Current Arrangement at the N2 Unit

Since modification is not an option, the usefulness of the controller is
very limited.
The control algorithm cannot be refined or modified as per
operational requirement.
A new program must be commissioned every time a modification is
required.
The program costs almost the same as the PLC and its associated
modules.

The Proposal
The nitrogen extraction algorithm is fairly simple and the program can
be developed in-house.
This would allow us access to the program for further modification
and eliminate the cost of having to commission the program.

The Proposal
The nitrogen extraction algorithm uses a total of ten digital outputs to
open and close SOVs as per a programmed timing sequence.
The timing sequence may be replicated by recording how the output
status LEDs light up on the DO card as nitrogen extraction is carried
out.

Logic Development
The timing sequence was first studied by making a recording of the
DO card while nitrogen extraction continued in the background.
The timing sequence is shown in the table below:
Valve

57 sec

0.5 sec

0.5 sec

1 sec

0.5 sec

SOV1

SOV2

SOV3

SOV6

SOV7

SOV8

0.5 sec
1

0.5 sec

0.5 sec

SOV9

SOV10

1 sec

SOV4
SOV5

57 sec

Nitrogen Extraction via

Pressure Swing Adsorption

Tank A

Inlet Air

10

Exhaust

Tank B

Outlet Air

Logic Development
A timer runs for a total 1 minute and 59 seconds.
It is used to regulate the entire process.
It provides a reference point against which each SOV is turned on or off.
It restarts the sequence after the 1 minute and 59 seconds mark.

Logic Development
The algorithm treats each SOV separately.
Comparison is made with the timers count to come up with the logic
for each SOV.
This can be seen by using SOV0 as an example.

Logic Development
The timing sequence only continues as long as the level switches of
the two CMS tanks are HIGH.
This indicates that the CMS level in the tanks is appropriate.
Each SOV either turns on once or it turns on twice in one given
iteration of the sequence.
The logic is presented in the next slide.

Start Scan
Cycle

Start Scan
Cycle

Are
LevelSwitch1
AND
LevelSwitch2
HIGH?

Are
LevelSwitch1
AND
LevelSwitch2
HIGH?

No

Yes

Yes
T >= x
AND
T <= x + range

Yes

No

No

(T >= x AND
T <= x + range1)
OR
(T >= y AND
T <= y + range2)

Yes

SOV = 1 for the

duration of one scan
cycle

SOV = 1 for the

duration of one scan
cycle

End Scan
Cycle

End Scan
Cycle

No

Cost Benefit Analysis

The cost of the program factors into the overall cost of procuring
spare PLCs for the N2 Unit.
By programming the PLC in house, we get to save money.
It also allows us to incorporate various interlocks into the logic as per
operational requirement.
PLC + Program
PLC
Money Saved

Rs. 235000
- Rs. 119000
Rs. 116000

Cost Benefit Analysis

We now have access to the program and we understand that its scope
is very simple from a control point of view.
We can therefore even go as far as replacing Siemens S7-200 PLC
with a cheaper option.
Before we look at alternatives that may replace the S7-200, we need
to list out the variables or parameters that determine their overall
performance. This is discussed in the appendix.

Appendix Room for Expansion

Parameter

Siemens S7-200
CPU 222

Siemens S7-200
CPU 224

Fatek FBs-24MA

Allen Bradleys
Micrologix 1000
1761-L32BWA

Program size

2048 words

4096 words

20K words

737 instruction words,

437 data words

Execution speed

0.37 s

0.37 s

0.33 s

No. of on-board digital

outputs

10

10

12

No. of on-board digital

inputs

14

14

20

Input current

4 mA nominal

4 mA nominal

7.6 mA nominal

8 mA nominal

Output current

0.75 A

0.75 A

0.5 A

8 A maximum

Communication
protocols supported

RS-485 (on-board),
Ethernet (expansion
module)

RS-485 (on-board),
Ethernet (expansion
module)

RS-232 (on-board), USB

(on-board) and Ethernet
(expansion module)

RS-232 (on-board) and

Ethernet (expansion
module)

Cost

Over 100k

Over 100k

Between 20k to 80k

Between 20k to 80k