Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Design and Implementation of Advanced Control Strategies for Boiler and Heat Exchanger Pilot Plant
Guided By: Prof. S. D. Agashe

Ms. Tejaswinee J. Darure MIS: 121116004

June 26, 2013

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Motivation

Academicians seldom get exposure to the actual industrial environment.

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Motivation

Academicians seldom get exposure to the actual industrial environment. Access to various control platforms under one roof is unavailable, for evaluation, comparison, etc.

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Motivation

Academicians seldom get exposure to the actual industrial environment. Access to various control platforms under one roof is unavailable, for evaluation, comparison, etc. Real-time data if available can be monumental in online/oine data analysis exercises.

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Objectives

Mathematical Modeling for Boiler and Heat Exchanger Pilot Plant

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Objectives

Mathematical Modeling for Boiler and Heat Exchanger Pilot Plant Concept to commissioning of Boiler and Heat Exchanger Pilot Plant

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Objectives

Mathematical Modeling for Boiler and Heat Exchanger Pilot Plant Concept to commissioning of Boiler and Heat Exchanger Pilot Plant Control from multiend and multiuser

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Outline

Mathematical Modeling Boiler Heat Exchanger

Pilot Plant Insight

Communication ControlLogix MATLAB DeltaV DCS

Control PID Controller Model Predictive Control

Conclusive Discussion

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Outline

Mathematical Modeling Boiler Heat Exchanger

Pilot Plant Insight

Communication ControlLogix MATLAB DeltaV DCS

Control PID Controller Model Predictive Control

Conclusive Discussion

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Boiler

Material Balance Equations:Mass Balance d {s Vst + w Vwt } dt = qf qs

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Boiler

Material Balance Equations:Mass Balance d {s Vst + w Vwt } dt Energy Balance d {s us Vst + w uw Vwt + mt Cp tm } dt = Q + qf hf + qw hw = qf qs

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Boiler
After solving, dVwt dt dp dt where: = = Qm12 + w qw (hf m12 m22 ) s qs (hs m12 m22 ) (m12 m21 m11 m22 )
wt w qw s qs m11 dV dt m12

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Boiler
After solving, dVwt dt dp dt where: m11 m12 m21 m22 = = ( w s ) (Vd Vwt ) = = Qm12 + w qw (hf m12 m22 ) s qs (hs m12 m22 ) (m12 m21 m11 m22 )
wt w qw s qs m11 dV dt m12

ds ds + Vwt dp dp = (w hw s hs ) dhs ds = (Vd Vwt ) s + hs dp dp

+ w V w

dhs dp

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Boiler

Figure: Simulation in MATLAB Simulink for Boiler

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Heat Exchanger

Figure: Countercurrent Heat Exchanger

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Heat Exchanger

Shell side (Outer Pipe)

1 2 3

Fluid Flow rate Temperature

Figure: Countercurrent Heat Exchanger

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Heat Exchanger

Shell side (Outer Pipe)

1 2 3

Fluid Flow rate Temperature

Tube side (Inner Pipe)

1 2

Figure: Countercurrent Heat Exchanger

Fluid Flow rate Temperature

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Heat Exchanger

Shell side (Outer Pipe)

1 2 3

Fluid Flow rate Temperature

Tube side (Inner Pipe)

1 2

Figure: Countercurrent Heat Exchanger

3 3

Fluid Flow rate Temperature

Flow Conguration

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Heat Exchanger

Shell side (Outer Pipe)

1 2 3

Fluid Flow rate Temperature

Tube side (Inner Pipe)

1 2

Figure: Countercurrent Heat Exchanger

3 3

Fluid Flow rate Temperature

Flow Conguration

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

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Figure: Simulation in MATLAB Simulink for Heat Exchanger

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Figure: Combined Model

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Outline

Mathematical Modeling Boiler Heat Exchanger

Pilot Plant Insight

Communication ControlLogix MATLAB DeltaV DCS

Control PID Controller Model Predictive Control

Conclusive Discussion

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

VPLC

TT1

LSHH2

PT

I/P

TT2

HOT WATER TANK

TSHH

PWM Controller

HEAT EXCHANGER

LSLL4 PSHH

LT

BOILER

FROM 3-PHASE SUPPLY

CONDESATE TANK

TT3 LSHH1 FT LSLL1

SOLENOID VALVE

VPLC VPLC

BOILER FEED WATER TANK

VFD1

VFD2

COLD WATER TANK

LSLL2

POSITIVE DISPLACEMENT PUMP

CENTRIFUGAL PUMP

LSLL3

NOTE: AREA INSIDE THE DARK BOX NOT IN VENDORS SCOPE

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Figure: Boiler and Heat Exchanger Pilot plant Pilot Plant

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

1 2 3 4 5 6

Level of water in the boiler drum (LT-1) Drum pressure (PT-1) Steam temperature (TT-1) Boiler feed water temperature (TT-5) Boiler feed water ow ((FT-2) Temperature from water from hot water tank for mixing with boiler feed water (TT-4) Steam ow (FT-3) Heat exchanger steam inlet temperature (TT-2) Heat exchanger water inlet temperature (TT-4) Heat exchanger water outlet temperature (TT-3) Heat exchanger water ow (FT-1)

7 8 9 10 11

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Local Control

Figure: Local Controllers

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Outline

Mathematical Modeling Boiler Heat Exchanger

Pilot Plant Insight

Communication ControlLogix MATLAB DeltaV DCS

Control PID Controller Model Predictive Control

Conclusive Discussion

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Communication Overview

Figure: Network Topology

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix
About ControLogix

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix
About ControLogix
Chassis Based Series 1756-L61

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix
About ControLogix
Chassis Based Series 1756-L61 RSlinx

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix
About ControLogix
Chassis Based Series 1756-L61 RSlinx

Figure: Network Topology

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

RsLogix 5000

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

RsLogix 5000 RSview Works

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

RsLogix 5000 RSview Works Procedure Ethernet IP protocol

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

RsLogix 5000 RSview Works Procedure Ethernet IP protocol Conguration

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

RsLogix 5000 RSview Works Procedure Ethernet IP protocol Conguration IP address: 169.254.104.223 Subnet mask: 255.255.0.0 Messaging

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

Figure: Messaging for AI and DI

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

Figure: Messaging for AI and DI

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

Figure: Flow for PLC program

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

Figure: Flow for PLC program

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

ControLogix

Figure: Flow for PLC program

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Figure: Network Topology

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Modbus RTU
Serial Communication Protocol Protocol Data Unit (PDU) Application Data Unit (ADU)

Figure: Data packet format in Modbus RTU

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Modbus RTU

Figure: Client Server topology

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Modbus RTU

Conguration Parameters Sr.No. 1 2 3 4 5 Parameter Baud Rate (bits/sec) Parity Stop bit Data Bits Time out Value 19200 None 1 8 0.1sec

Table: Conguration for Serial Port

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

MATLAB

Read Data Initialization of serial port s=serial(COM1); set(s,BaudRate,19200) set(s,Timeout,0.1) get(s) fopen(s); this opens the port fcloses; this opens the port txdata=gen-pdu-read(AI/DI Modbus address ) fwrite(s,txdata,uint8) rxdata-dec=fread(s)

Write Data txdata=gen-pdu-write(AO/DO Modbus address,value ) fwrite(s,txdata,uint8)

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: Network Topology

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: Location of Serial Card in DeltaV

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: Adding new device:Micrologix 1400 PLC

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: Device address and description of slave

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: New Device added

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: Dene description and data direction

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: dene PLC data type and register oset and number

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: Add DeltaV data type and tag name foe dataset

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: Example for data tag name

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

DeltaV DCS

Figure: Table of Registers created

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Thus data can be written and read in each end:1 2 3 4

Micrologix PLC Contrologix PLC using Ethernet IP protocol MATLAB/VPLC/VDCS using MODBUS protocol DeltaV DCS using MODBUS protocol

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Outline

Mathematical Modeling Boiler Heat Exchanger

Pilot Plant Insight

Communication ControlLogix MATLAB DeltaV DCS

Control PID Controller Model Predictive Control

Conclusive Discussion

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Plant Control

Sr.No. 1

Controlled Variable Boiler Level

2 3

Boiler Temperature Heat Exchanger Outlet Temperature

Manipulated Variable Feed Pump Speed Or Steam ow rate SCR Cold water pump speed Or Control Valve

Table: List of controlled and corresponding manipulated variable

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

VDCS

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

Figure: Flow for PLC program

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

Routines and their scope SR.No. 1 2 3 4 5 Routine Name Main Data In Interlock Plant mode Control Logic Function decides execution sequence real time data is received through messaging check for low and high limits plant start and stop control implementation controllers (PID)

Table: Routines and their scope

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

Figure: Run ans Stop mode for plant

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

Interlocks for safety SR.No. 1 2 3 4 5 Process Variable LT-1 TT-1 PT-1 LSH-201 LSH-101 Limit 75% 1450 C 3.7 bar =1 =1 Corrective action Heater OFF Heater OFF Heater OFF Pump-301 OFF Pump-101 OFF

Table: Interlock with corresponding action

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

View in RsLogix5000

Figure: Run ans Stop mode for plant

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

PID block

Figure: PID controller implemented in FBD programming

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

PID block

Figure: PID controller implemented in Ladder programming

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

Data Logging

Figure: PID controller implemented in FBD programming

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

Data Logging setup

Figure: PID controller implemented in FBD programming

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through ControLogix

SCADA

Figure: SCADA in RSView32 Works

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through DeltaV DCS

Figure: Plant Mode in DCS

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through DeltaV DCS

Figure: Location of Boiler and Heat Exchanger

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through DeltaV DCS

Figure: PID implementation in Control Studio

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through DeltaV DCS

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through DeltaV DCS

Figure: Graphics developed in Operate gure

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through DeltaV DCS

Figure: TuneInsight tool

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Control through DeltaV DCS

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Model Predictive Control Overview

MPC includes following ideas,

1

Explicit use of a model to predict the process output along a future time horizon Calculation of a control sequence to optimize a performance index A receding horizon strategy, so that at each instant the horizon is moved towards the future, which involves the application of the rst control signal of the sequence calculated at each step.

2 3

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

MPC in DeltaV DCS

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

MPC in DeltaV DCS

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Outline

Mathematical Modeling Boiler Heat Exchanger

Pilot Plant Insight

Communication ControlLogix MATLAB DeltaV DCS

Control PID Controller Model Predictive Control

Conclusive Discussion

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Conclusive Discussion

The pilot plant is interfaced through various controllers using Modbus 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 driven modeling, where samples were collected at each-end irrespective of active or passive master. For instant analysis, online trends are also congured at every end.

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger

1 2

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware

1 2 3

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability

1 2 3 4

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol

1 2 3 4 5

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol

1 2 3 4 5

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety

1 2 3 4 5

6 7

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety Daisy Chaining for ControLogix and DCS

1 2 3 4 5

6 7 8

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety Daisy Chaining for ControLogix and DCS Control strategies at each-end

1 2 3 4 5

6 7 8 9

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety Daisy Chaining for ControLogix and DCS Control strategies at each-end Testing and Control through VPLC and VDCS

1 2 3 4 5

6 7 8 9 10

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Goals Achieved
Unit Operation Insight Mathematical Modeling of Boiler and Heat Exchanger Installation and Testing of hardware Local Control Capability Serial Communication of plant to PC/DCS using Modbus RTU protocol Communication with ControLogix using Ethernet/IP protocol Plant Safety Daisy Chaining for ControLogix and DCS Control strategies at each-end Testing and Control through VPLC and VDCS Implementation of control strategies on setup (Partially)

1 2 3 4 5

6 7 8 9 10 11

Motivation

Modeling

Pilot Plant

Local Control

Communication

Control

Conclusion

Achievements

Thank You