BOILER LEVEL CONTROL USING LABVIEW

MAIN PROJECT REPORT

Submitted in partial fulfillment of the requirement for the degree of BACHELOR OF TECHNOLOGY in Applied Electronics & Instrumentation of Mahatma Gandhi University by DELFIN DAVID

DEPARTMENT OF APPLIED ELECTRONICS & INSTRUMENTATION

RAJAGIRI SCHOOL OF ENGINEERING & TECHNOLOGY RAJAGIRI VALLEY, KAKKANAD, COCHIN 682 039
2012

RAJAGIRI SCHOOL OF ENGINEERING & TECHNOLOGY

RAJAGIRI VALLEY, KAKKANAD, COCHIN - 682 039

DEPARTMENT OF APPLIED ELECTRONICS & INSTRUMENTATION

CERTIFICATE
Certified that this document titled BOILER CONTROL USING LABVIEW is a bonafide record of the main project done by DELFIN DAVID of 8th semester, Applied Electronics and Instrumentation in partial fulfillment of the requirement for the award of Degree of Bachelor of Technology of Mahatma Gandhi University, Kottayam, during the academic year 2012.
Mr.Anish.T. Department of AEI RSET, Kakkanad Ms. Liza Annie Joseph (HOD) Department of AE&I RSET, Kakkanad

Internal Examiner

ACKNOWLEDGEMENT

I would like to extend my sincere thanks to my project guide Mr.Anish.T. ,Ms .Aparna George for her constant help and support. I also thank Prof. Madhava Panicker, our class associate Mr. Krishnakumar K.P, and other staff members of our college for providing timely guidance and help. I would also like to thank Ms. Liza Annie Joseph, HoD, AEI, Dr. J Issac, principal, RSET for providing all the facilities in our college. I am also thankful to all my friends for their valuable contributions. We express our sincere gratitude to Mr.Goplalakrishnan K.V, Manager (Instrumentation) , FACT Petrochemical Division and Mr.Sivadasan K.O ,Engineer(Instrumentation) ,FACT Petrochemical Division for their guidance and cooperation. Their stimulating and suggestions and encouragement helped us during the entire course of the project. Last but not the least I thank the Lord Almighty for his blessings which enabled me to complete my seminar successfully.

ABSTRACT

A boiler system is an integral component of a sugar plant and control of water level in the drum of the boiler is a critical operational consideration. Nowadays, instead of conventional control techniques, modern control techniques have been implemented for a lot of industrial models practically or theoretically. In this paper, we describe the effectiveness of LabVIEW in order to provide better drum level control of various products evolved in a sugarcane industry. The project is scheduled at FACT Ltd. Udyogamandal. FACT is a leading producer of fertilizers like Caprolactum in the country. The power required for the operation of these plants is developed by generating steam from the captive power plant(CPP). CPP consists of three boilers, which are capable of producing 60tons of superheated steam per hour with a temperature of 5200 C and a pressure of 110 ATA and this steam is supplied to all major steam lines. The boiler water/steam drum, or steam drum, is an integral part of the boilers design. Efficient operation of these boilers requires automatic control schemes for Drum water level ,Air-to-fuel flow rates(Combustion control),steam temperature and Furnace pressure. Drum level control (Feed water control) is one of the important controls required for safe and efficient operation of boilers. Three-element control (water level, steam flow, feed water)is preferred over single or two-element control for industrial and utility purposes where wide and rapid load changes occur frequently.3-element control
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scheme also attenuates shrink and swell effect due to load transients. For disturbance rejection purposes Cascade and feed-forward control strategies are used. Main controller is the feed water controller which is of PID type. The tuning of parameters for traditional PID controllers is based on the mathematical model of the object and some control rules, which is difficult to adapt to complicated and variable control systems such as boiler drum level control.

CONTENTS
CHAPTER 1: Introduction......6 CHAPTER 2: ..8 CHAPTER 3: ...12 CHAPTER 4: ...........15 CHAPTER 5: .......20 CHAPTER 6: .......21

CHAPTER 1 INTRODUCTION The dynamic behavior of industrial plants heavily depends on disturbances and in particular on changes in operating point. The main input variables of a sugarcane plant are fuel, feedwater and air. The outputs of the system are electrical power, steam pressure, steam temperature, flue gas as shown in Figure 1.

Some of the inputs and outputs are more important than the others since these are adequate for modeling the plant. These are fuel feed and feedwater flow as the inputs, and the electrical power and steam enthalpy as the outputs [1]. The conventional systems today at Sugarcane industries are operated using PLCs and DCS which requires professionalism with higher technical abilities so as to operate the same. LabVIEW has been emerging onto each and every field evolving broader scope of improvement at every level .The graphical user interface is a key factor which simplifies the scope of learning compared to the
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above mentioned. In addition, the training period required is of short duration compared to PLCs and DCS. LabVIEW also increases the comfort levels of the persons working at the plant and acts as a substitute for the DCS system installed in the control room. Keeping this view in mind this paper is being put up in order to improvise on the level control in the boiler, efficiency and quality of the product obtained with the maximum utilization of the available resources so that the transition would provide better stand-alone system, a cut above the existing technologies. The simulation results show that the PID [4] controller developed in this study performs better than the rest controllers on the settling time and overshoot of power and enthalpy outputs. Standard virtual instrumentation software is structure effectively to perform both user -end and process /machine level tasks. The user process takes care of all the front-end functions that graphical programs can be developed, modified and redeployed to absorb maximum human flexibility as required in a teaching or training environment. The graphical software creates virtual instruments (VIs) developing block-diagrams using nodes, terminals and wires. With the icon/connector, a VI can be used as a Sub VI in the block diagram of another VI. All advanced programming techniques with add-on tools and libraries can be graphically represented with minimum amount of coding-hours in this environment. The web interface and interactivity in the deployed VI modules has used Control Design and Simulation module linked to LabVIEW.