BOILER AUTOMATION

INTRODUCTION:-

Todays Industrial environment is changing from manual to semiautomation and semi-automation to fully automation. In all these feasibilitys process control plays a vital role. Also most probably the process Control is via analog, digital circuitry. The designer selects the appropriate system, depending upon the usefulness & cost to performance ratio. Boiler automation & control is our proposed project. Here the steam pressure & temperature are sensed, indicated and controlled separately. The boiler system will be working only when temp and pressure are within safe limits Boilers are available in two basic designs. 1) Fire Tube Boiler 2) Water Tube Boiler Our aim is to prove the automation in boilers; hence source of heat is not so importance. After excessive heat exit valve should be open or heat sourcing element should be stop. In boiler automation following process parameters are too controlled. 1) Temperature of steam 2) Pressure of steam 3) Water level in the drum
BLOCK DIAGRAM ADC SV 1 BOILER SV 2 PT 100 Pressure Sensor Level Sensor CV1 Heater Switching Block Relay Driver & Relay Regulated Power Supply Signal Conditioning Signal Conditioning Comparator Pressure Display Temp Display

ADC Comparator

SV1:- Solenoid valve for drain outlet. SV2:- Solenoid valve for level inlet. SV3:- Solenoid valve for outlet.

BOILER WORKING:The control system is made ON as and when required. The important requirement in the boiler application is that it should produce steam at high temperature and pressure, to achieve the well work efficiency. This steam is used for rotating the turbines, which is useful for running the process plants. We are using the heater as the heat sourcing element. BLOCK DIAGRAM DESCRIPTION:As shown in the block dia. the temp and the pressure of the steam is sensed by the sensors. PT 100 is used for temp sensing. It converts the temp in to electrical signal i.e. resistance. As the temp increases the resistance increases and vice versa. This is then calibrated and signal conditioned in the signal condition block. Here the temp. 0C in terms of milivolts is received. This is given to ADC for indication purpose. In ADC analog signal is converted onto digital form and shown on the digital display. This indicated signal is also available at one of the input of comparator. The comparator has one more input i.e. set point. The set point is generated on the same board. It is also shown on ADC. Depending upon the comparator inputs its o/p is toggles between high and low. As the comparator o/p is low the relay will be off and the heater will be made ON till the temp reaches the set point. It becomes OFF when the actual temp goes below set point. As the steam temp goes below set point by 20C then heater will be ON again. This happens repeatedly and thus temp control of the steam has been done. Strain gauge type sensor is used for pressure sensing. It converts the pressure in to electrical signal i.e. mill volt. As the pressure increases the millivolts increases and vice versa. This is then calibrated and signal conditioned in the signal condition block. Here the pressure in terms of mili volts is received. This is given to ADC for indication purpose. In ADC analog signal is converted onto digital form and shown on the digital display. This indicated signal is also available at one of the input of comparator. The comparator has one more input i.e. set point. The set point is generated on the same board. It is also shown on ADC. Depending upon the comparator inputs its o/p is toggles between high and low. As the comparator o/p is low the relay will be off and the solenoid valve will be off till the pressure reaches the set point. It becomes ON when the actual pressure crosses set point. As the steam pressure goes above set point by 1 Kg/cm2 then solenoid valve will be ON again. This happens repeatedly and thus pressure control of the steam has been done. Also in addition we have observed the steam pressure so as to take the safety cautions. For this purpose we have use the pressure gauge. Water level in a boiler drum is also important. Hence level sensors are installed inside the water drum. As the water level decreases the solenoid valve is open and water

passes in the drum . As level in the drum increases the solenoid is closed. Also this level is indicated by LED lamps. Thus boiler automation is achieved with the help of the electronic circuitry.

APPLICATIONS: Sugar Industry Paper Industry Pharmaceutical Industry Chemical industry