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AUTOMATION OF SYSTEM OF BOILER

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					   AUTOMATION OF
  BMS SYSTEM OF
   BOILER USING
PLC LADDER LOGIC

                   Authorised By
          SANTOSH BHARADWAJ REDDY
          Email: help@matlabcodes.com
         Engineeringpapers.blogspot.com
More Papers and Presentations available on above site
                          ABSTRACT
The problem of operation and safety posed by a Recovery Boiler is much
more than a conventional utility/Industrial Boiler. The Black Liquor from
Pulp Mill is acquired by Evaporator which is sent to Liquor Fired Boiler.
Recovery Boiler is basically a chemical recovery process unit where the
organic material in the black liquor is burnt, while the sodium salt is
reduced and drained as molten smelt from the furnace bottom.
At the same time, Super Heated Steam which is the byproduct is utilized
for steam generation. Flue Gas is sent out through Chimney through I.D
Fan. The Green Liquor is sent to Causticizing Plant for Generation of
White Liquor.
The BMS System is a part of LIQUOR FIRED BOILER(LFB 5) of Soda
Recovery Plant. HoneyWell PLC is used to study the BMS System in
BOILER Plant..
In LFB5 the BMS system includes Primary, Secondary/Tertiary fans,
Liquor Guns, Oil Burner Valves, Induced Draft Fan, Electrostatic
Precipitator, Economizers, Steam/ Mud Drum, Furnace and Pumps to
circulate water .

In BMS system the Furnace is first Purged completely i.e., to flush the
Furnace with fresh air. In this duration of Purging (120ms) all valves
should be closed.
The BMS provides for the proper sequencing of equipment during the
normal startup operating and shut down procedures and provides for an
auxiliary fuel trip and/or an alarm during an adverse burner or unit
operating condition.

This is accomplished through the use of pre-wired logic and various
Interlocks.

The Industrial parameters like Temperature, Pressure, Flow, Level are
The Implementation section includes Level Control in a Reaction
Vessel which is performed using Siemens PLC.
 In Level Control 4 Digital Inputs and 6 Digital Outputs are used. So ,
taking a prototype of Level Control, I try to use PLC to automate the
process.
Initially, the Liquid-1 is filled into Tank/Vessel using a pump via Inlet
valve-1. There are 3 levels namely Low, Medium, High. When Low and
Medium levels are reached Inlet valve-1 stops and Inlet valve-2 supplies
Liquid-2 until the High Level is reached.
Then Motor mixes both the Liquids for the specified time, the mixture is
drained out through Outlet valve.
Timing is to be maintained for running of Motor. Considering the PLC,
digital input is taken from limit switch.
The programming can be done by using various Simulation softwares
like
VERSAMAX
SIMATIC S7 etc.
              JK PAPER MILLS PROCESS FLOW DIAGRAM
 Raw materials                                                             Dust
                    Chipper House
Mixed Hard Wood
                                                            White Liquor
   & Bamboo                                                                                                            Coal Handling
                       Digestor                                                           Causticizing Plant
                                                  Weak                                                                     Plant
                                                  Black
                       Washing /                  Liquor                                     Chemical
                                                              Evaporator
                       Screening                                                           Recovery Boiler
                                                                                                   Steam
   Oxygen              Oxygen                                                                                  Steam
Generation Plant    Delignification                Power distribution for                 Turbo Generator                 Coal Fired
                                                     Process & Colony                           Set                        Boilers
                   Unbleached Pulp                                                                  Steam
                       Storage                  DG Set         Grid Power
Chlorine Dioxide      Bleaching                                                            Process Plants
      Plant         (CD + EOP +D)
                     Bleached Pulp
                                            Pulp Drying Plant
                        Storage

                   Stock Preparation

                                      Coating
                                                         Rewinders           Cutters
                                       Plant


                    Paper Machines                Rewinders                  Cutters            Finishing House        Sales Godown

                                                                           Wills Cutter
                                                                                                                         Market
   BAMBOO            WHITE LIQUOR
      &
    WOOD




STEAM
                            Pulp to Paper
                               Process
   WBL :16-18%



EVAPORATOR




                                            LIME   RECAUSTICIZING STEAM
    CBL :55%-65%                                       AREA
                                    WWL
STEAM
                   SMELT
RECOVERY
 BOILER
                                     G/L
INTRODUCTION
 BMS stands for „BURNER MANAGEMENT
  SYSTEM‟. It is a part of Liquor Fired Boiler in Soda
  Recovery Section.
 The problem of operation and safety posed by a
  Recovery Boiler is much more than a conventional
  utility/Industrial Boiler.
 It is basically a chemical recovery process unit where
  the organic material in the black liquor is burnt, while
  the sodium salt is reduced and drained as molten smelt
  from the furnace bottom. At the same time, the heat
  released is utilized for steam generation.
 Though predominantly the heat for the process is obtained
  from the burning of the black liquor, supplementary heat
  from oil fired auxiliary fuel burners is required to start up
  the unit, regulate the char bed , avoid blackouts and to
  augment additional steam.

 Here we are using PLC Programming and developed
  Ladder Logic for Inputs and Outputs. The inputs and
  Outputs are Digital ones.

 The PLC used for BMS is HONEYWELL 620-35 PLC.
  Software used is 620 WINLOADER Version 5.4 .
                          LIQUOR FIRED BOILER
                                                                       SUPER HEATED/ DRY STEAM to TURBINE
                          SATURATED STEAM
                                                 SUPER HEATER
                                                                                                        FLUE GAS
                                                                                                       TO CHIMNEY


                                                                    FLUE GAS                         ID
                                     FURNACE                                        ESP
                                                                                                    FAN
 PULP            WHITE
 MILL            LIQUOR
                                                SMELT
                                                                                 DUST
        WBL                                 MUD
                                        DISSOLVER                WWL
                                                                                 ESP ASH TANK
STORAGE                                    TANK
 TANKS                                  87-95 DEG.C                     Na2SO4
                  PUMP                             G/L

                                                                                      SALT
                                      CAUSTICIZING
                                                                                     CAKE
      EVAPORATORS                        PLANT
                                                                                  MIXING TANK
    THICK
 BLACK LIQUOR

             CBL
        STORAGE TANKS                         SECONDARY                INDIRECT   HBL
                                                HEATER                  HEATER
   60-65 DEG.C
                                  118 DEG.C                     112 DEG.C         102 DEG.C
                                              BMS SECTION
                                                                  SUPER HEATED/ DRY STEAM to TURBINE
                        SATURATED STEAM
                                                  SUPER HEATER


S
T                                 STEAM
E                                 DRUM                                         FLUE                ESP             ID
A                                                                              GAS               PLATES           FAN
M




                                                    FLUE
               HBL                                  GAS
              pump

       SCMT
S
T
E
A
M
                                                                                                HAMMERS

                           FLUE
                           GAS                                                                             DUST


pump                                                                                             ESP ASH
                                                                                                  TANK
                 SA /
                 TA
                 FA
    DAY           N                                                                         FEED WATER
     OIL                                                                                       PUMP
    TANK
                 PA
                 FA
                 N
                         FIRING
                          ZONE             MUD
                                           DRUM
       IGNITOR                                                   ECONOMIZERS
                                             SPOUT
                                              TANK



                                          SMELT
THEORY
  of
 BMS
                    FEATURES
• The BMS provides for the proper sequencing of equipment
  during the normal startup operating and shut down procedures
  and provides for an Auxiliary fuel trip and/or an Alarm during
  an adverse burner or unit operating condition.
• This is accomplished through the use of pre-wired logic and
  various Interlocks.
• The BMS is a local-manual relay system.
• Starting burners are started and stopped locally from their
  associated local switch boxes while the various header trip
  valves are opened and closed remotely from associated Push
  Buttons on BOILER CONTROL DESK(BCD).
                                                  BMS PANEL
BURNER
   1

         BURNE   BURNE   OIL GUN     HEA        HEA      ATOMISIN   ATOMISIN   BURNER   BURNER   SCAVENG   SCAVENG     FLAME       FLAME SCANNER
          R ON     R     ENGAGE    IGNITOR    IGNITOR       G          G                  V/V       E         E       SCANNER
                                                                                 V/V                                                 SHOWS NO
                  OFF      D       ADVANCED   RETRACTE     V/V        V/V      OPENED   CLOSED     V/V       V/V     SHOWS FLAME       FLAME
                                                 D       OPENED     CLOSED                       OPENED    CLOSED




BURNER
   2

         BURNE   BURNE   OIL GUN     HEA        HEA      ATOMISIN   ATOMISIN   BURNER   BURNER   SCAVENG   SCAVENG     FLAME       FLAME SCANNER
          R ON     R     ENGAGE    IGNITOR    IGNITOR       G          G                  V/V       E         E       SCANNER
                                                                                 V/V                                                 SHOWS NO
                  OFF      D       ADVANCED   RETRACTE     V/V        V/V      OPENED   CLOSED     V/V       V/V     SHOWS FLAME       FLAME
                                                 D       OPENED     CLOSED                       OPENED    CLOSED




BURNER
   3

         BURNE   BURNE   OIL GUN      HEA        HEA     ATOMISIN   ATOMISIN   BURNER   BURNER   SCAVENG   SCAVENG     FLAME       FLAME SCANNER
          R ON     R     ENGAGE     IGNITOR    IGNITOR      G          G                  V/V       E         E       SCANNER
                                                                                 V/V                                                 SHOWS NO
                  OFF      D       ADVANCED   RETRACTE     V/V        V/V      OPENED   CLOSED     V/V       V/V     SHOWS FLAME       FLAME
                                                 D       OPENED     CLOSED                       OPENED    CLOSED




BURNER
   4

         BURNE   BURNE   OIL GUN      HEA        HEA     ATOMISIN   ATOMISIN   BURNER   BURNER   SCAVENG   SCAVENG      FLAME      FLAME SCANNER
          R ON     R     ENGAGE     IGNITOR    IGNITOR      G          G                  V/V       E         E        SCANNER
                                                                                 V/V                                                 SHOWS NO
                  OFF      D       ADVANCED   RETRACTE     V/V         V/V     OPENED   CLOSED     V/V       V/V     SHOWS FLAME       FLAME
                                                 D       OPENED      CLOSED                      OPENED    CLOSED
    BOILER                                                                                                                        EMERGENCY
EMERGENCY                                                                                                                         DRAIN & TRIP
   TRIP
                                 AUXILIARY                                          AUXILIARY
                                 FUEL TRIP                                          FUEL TRIP
                                   PUSH                                               PUSH
                                  BUTTON                                             BUTTON




    NO                               BOILER                             AUXILIA                                     EMERGENCY
  BOILER                              TRIP                                RY                                           DRAIN &
   TRIP                                                                  FUEL                                         TRIP NOT
                                                                         TRIP                                        ACTIVATED




    ID       SA/TA    PA FAN     BLACK         ID FAN         SA/TA     PURGE       START        PURGE      PURGE         ALL      ATOMIS        ATOMISI
   FAN        FAN     START     LIQUOR        RUNNING          FAN      READY       PURGE          IN       COMPL      EMERGEN       ING           NG
   STAR      STAR     PERMI      PUMP                        RUNNIN                  PUSH        PROGR       ETE       CY DRAIN    STEAM          STEAM
     T          T       T        START                          G                   BUTTO         ESS                    V/V S     PRESS         PRESSU
   PER       PERM               PERMIT                                                 N                                CLOSED      URE          RE HIGH
    MIT        IT                                                                                                                   LOW




               HO        HO     PRECIPITA       PRECIPITAT      FEED        ALL            AIR        AIR     DRUM        DRUM        FURNA        FURNAC
             PRESS     TEMPE       TOR              OR         WATER      SCANNE          FLOW       FLOW     LEVEL       LEVEL         CE            E
              URE      RATUR     OUTLET          OUTLET                       R                      <30%     VERY                    PRESS        PRESSU
                                                              SHUTOFF                     <30%                            VERY
              LOW         E       TEMP.           TEMP.                    SHOW                                LOW        HIGH         URE           RE
                                                               VALVE
                        LOW        >270         <270 DEG.C                   NO                                                        VERY         VERY
                                                              CLOSED
                                  DEG.C                                    FLAME                                                       LOW          HIGH




                LAM            OPE       CLOS           OPE                       STAR       STOP               START       STOP
                                                                 CLOS
                 P              N          E             N                          T                          SCANNE
                                                                   E                        SCANNE                         SCANN
                TES            HOT       HOTV           HOR                       SCAN         R                  R          ER
                                                                 HORV
                 T              V                        V                         NER                          FAN-B
                                                                                             FAN-A                         FAN-B
                                                                                  FAN-A
                        FUNCTION
• The following operations of the function are achieved in the
  BMS.
• Boiler purge.
• Main oil header trip valve open/close operation.
• Ignitor oil header trip valve open/close operation.
• Auxiliary fuel burner ignitor „ON/OFF‟ operation.
• Ignitor Flame scanning.
• Auxiliary fuel burner start/stop operation.
• Auxiliary fuel trip production.
• Emergency drain trip protection.
               FURNACE PURGE
• Before any auxiliary fuel can be introduced in the unit(initial
  or after an auxiliary fuel trip)a satisfactory furnace purge cycle
  must first be completed. To start a furnace purge cycle,
  proceed as follows:
• Establish an (I.D. Fan Start,Permissive)by completing all of
  the following conditions.
• *1A. All Emergency drain valves are closed.
• *1B. Main oil header trip valve and ignitor trip valve closed.
• *1C. Feed Water shut off valve is open.
• 1D. Evaporator outlet temperature less than 525oF.
• 1E. Precipitator outlet temperature less than 525oF.
• (*) Conditions preceded by an asterish are not required once
  the ID fan is running.
• 2. Place I.D. Fan in service.
• 3. Place the Fans in service.
• 4. Adjust the primary air flow to maintain a minimum of 30%
  of full load air flow.
• 5. See that all of the starting and all of the load carrying burner
  valves are fully closed.
• 6. Reset the boiler trip by depressing the BOILER TRIP
  RESET Push Button.
• 7. When the purge ready light comes on indicating that all of
  the purge requirements have been completed depress the
  PURGE START PUSH BUTTON.
            TRIP VALVE OPERATION
MAIN OIL HEADER TRIP VALVE:
• Depressing the main oil header trip valve open push button
  once the furnace purge is completed, will open the main oil
  header trip valve.
• If the trip valve fails to open, check to see that,
• All burner valves closed.
• No auxiliary fuel trip exists.
• As the trip valve moves from fully closed position the „Main
  Oil Header trip valve‟ Open light comes on. When the trip
  valve has been fully opened, the main oil header trip valve
  closed light goes out. Once the trip valve is fully open, it will
  be in „OPEN‟ position.
                       OIL BURNER VALVE


                                                                     STEAM




  DAY                                                              SCAVENGE V/V          FURNACE

  OIL

  TANK
                                                                                  HOBV
                     HEATER



                                                                 HORV
FURNACE OIL   PUMP             PRESSURE             PRESSURE             OIL
                                            HOTV                 3 WAY
                              CONTROL V/V          CONTROL V/V
                                                                   V/V
                              15.0 Kg/cm2           8.0 Kg/cm2
             AUXILIARY FUEL TRIP
• Any one of the conditions below will cause an auxiliary fuel
  trip to occur,and results in the immediate shutdown of all of
  the auxiliary fuel in service and necessitates completion of
  another furnace purge cycle before any auxiliary fuel firing
  may be reinstated.
• Evaporator outlet temperature greater than 525oF.
• Precipitator outlet temperature greater than 525oF.
• I.D. Fan not in service.
• Fans not in service.
• Primary Air Flow less than 30% of full load of flow.
• Furnace pressure greater than +4”W.G.
• Ignitor oil pressure not within controlled limits.(75% to 125%
  of full load pressure).
• Ignitor air pressure greater than 75% of full load pressure.
• Main oil pressure below 75% of full load pressure .
• Starting burner oil header pressure above 125% of full load
  pressure.
• Load carrying burner oil pressure above 125% of full load
  pressure.
• Recirculation selector switch not in OPERATE position.
• A Boiler trip condition exists.
• Either of the local auxiliary fuel trip push button depressed.
• Both of the auxiliary fuel trip push buttons on the BCD
  depressed.
                                       LIQUOR SPRAY GUN


                        ESP            SALT CAKE



   CBL
                          ESP DUST
  TANK                                        Na2SO4




                         ESP
                         ASH                           PRESSURE
                                       SCMT            CONTROL                    DIREC
                        TANK                                         INDIRE                           FLOW   FURNAC
                                                         V/V                        T                           E
                                                                       CT                             METE
                                                                                  HEATE
 CBL                                                                 HEATER                             R
                                                                                    R
PUMP                                          HBL        102 DEG.C        112 DEG.C       118 DEG.C
         ESP ASH TANK                            HBL
                                 ASH
             LEVEL                              PUMP
                                PUMP
           CONTROL
              V/V
       EMERGENCY DRAIN AND TRIP
• An emergency drain and trip procedure is initiated if water in
  any amount is known to be entering the furnace and cannot be
  stopped immediately or if any leaks external to the furnace
  such as failure of gaskets, gage glasses etc.
• An emergency drain is initiated by simultaneously depressing
  the two “Emergency Drain push button” on the BCD panel.
• An emergency drain trip initiates the following.
• *1. Auxiliary fuel trip.
• *2. Fan trip.
• 3. Closing of the feed water valve.
• 4. Opening of the emergency drain valve.
•     * Conditions preceded by an asterisk are the same trip
  inputs .
                    BOILER TRIP
• A boiler trip condition exists when both the boiler trip push
  buttons on the BCD pane are depressed or when emergency
  drain is initiated. A boiler trip initiates the following.
• a. Auxiliary fuel trip.
• b. P.A,S.A/T.A Fan trip.
• c. Black liquor pump trip.
• Depressing the two emergency drain push buttons results in an
  instantaneous boiler trip. The feed water supply valve will not
  close, however, until the following conditions are also satisfied.
   – All trip valves closed           OR
   – Ignitor trip valve closed and
• All oil scanner valves closed.
• The emergency drain valves should not open until the feed-
  water valve is closed (This is an externally interlocked circuit).
                        Alarms

• The following alarm conditions will cause an annunciator
  alarm to sound if the appropriate terminals on the BCD panel
  are connected to the customers annunciators. The contacts are
  normally open for the alarm conditions.
• Furnace pressure greater than +4”W.G.
• Air flow less than 30%.
• Ignitor oil pressure less than 75%.
• Ignitor air pressure less than 75%.
• Main oil pressure less than 75%.
• Starting Burner Oil pressure greater than 125%.
• Boiler trip.
• Auxiliary fuel trip.
•   I.D. Fan not running.
•   Fans not running.
•   Precipitator outlet temperature greater than 525oF.
•   Feedwater shut off valve not open.
•   Emergency drain valves not closed.
•   Evaporator outlet temperature greater than 525oF.
•   Emergency drain and trip.
  ECONOMIZER:
 In boilers, economizers are heat exchange devices that heat
  fluids, usually water, up to but not normally beyond the boiling
  point of that fluid.
 Economizers are so named because they can make use of the
  enthalpy in fluid streams that are hot, but not hot enough to be
  used in a boiler, thereby recovering more useful enthalpy and
  improving the boiler's efficiency. They are a device fitted to a
  boiler which saves energy by using the exhaust gases from the
  boiler to preheat the cold water used to fill it (the feed water).
PLC used in BMS
•   PLC used is TATA HONEYWELL.
•   CPU : IPC 620-35.
•   SOFTWARE : 620 WINLOADER,VERSION 5.4
•   DC POWER SUPPLY
•   DI‟S : 26, DO‟S : 25.
•   INPUT : 110V/220V or 240V,5.5A Max.
•   OUTPUT : 25V DC,20A.
•   FREQUENCY : 50 HZ.
    PLC SPECIFICATIONS :-
•   32K EXPANDABLE MEMORY.
•   PLC used is a Redundant System.
•   I/O Handling Capacity : 2048 Real IO‟s.
•   Scan Rate : 50msec.
 The PLC used for BMS is HONEYWELL 620-35 PLC. Software
  used is 620 WINLOADER Version 5.4 .
 PLC consists of 5 Modules:
1) Memory module
2) Register module
3) System Control module
4) Processor module
5) I/O Control module.
 The PLC is Redundant type.
• Redundant system has Running mode and Standby mode
  slots.
• If Running mode wont work then Standby mode is used by
  PLC for functioning.
A Key is present in the PLC.
It has four modes:
1. Program
2. Disable
3. Run/Prog.
4. Run
LADDER LOGICS
 NO BOILER TRIP   AUXILLIARY FUEL                        HOTV     AUXILLIARY FUEL PURGE      PURGE
                  TRIP                                   CLOSED   TRIP            COMPLETE   READY


     112              3065          2301   2302   2303     3043     160          368            557




                    3066




•The Condition for Purge Ready is satisfied when Boiler is in healthy
condition, AFT occurs due to pressure difference. Other interlocks are
Header Oil v/v should be closed and Purge Complete is kept active
low.
  SA/TA FAN   AIR FLOW PA FAN    FURNACE    FURNACE     DRUM LEVEL     DRUM LEVEL   ID FAN   ID FAN
  RUNNING     >30%     RUNNING   PRESSURE   PRESSURE    VERY LOW       VERY HIGH    START    RUNNING
                                 VERY LOW   VERY HIGH                               PERMIT




      3051      3048    3053         3032     3033        3049       3050           115      3052      2301




•The output coil 2301 is a flag and it is Energized when
Secondary/Tertiary Fan shall be running that supplies Air flow > 30%
to Upper layer of Furnace, Primary Fan should also run that supplies
Air to Lower layer of Furnace.
•The Furnace Pressure and Drum level should be low and ID Fan
should start running for flue gas to be sent out.
   B-1 SCANNER   B-2 SCANNER   B-3 SCANNER   B-4 SCANNER   B1-4 SCANNER
   SHOW FILM     SHOW FILM     SHOW FILM     SHOW FILM     SHOW FILM



                                                             2302
     3002        3007          3018          3023




•The Scanner Film is present at Furnace through which the level, flow
are monitored. So, the I/Ps should remain active low.
  B-1 HOBV   B-2 HOBV   B-3 HOBV   B-4 HOBV                B1-4 HOBV
  CLOSED     CLOSED     CLOSED     CLOSED                  CLOSED




    3001     3006       3017       3022                      2303




•During Purge Ready initially the Furnace is Purged with fresh Air. So,
the Header Oil Burner v/vs B1-B4 should be closed.
     INDUSTRIAL SPECIFICATIONS
• FURNACE TEMP. : 600deg.C(inlet),650deg.C
• FURNACE STEAM: 35TPH
• ECONOMISER TEMP. :
  380deg.C(inlet) ,   160deg.C(outlet)
• ESP TEMP. : 160deg.C(inlet),150deg.C(outlet)
• STEAM DRUM WATER LEVEL : 54%
• SUPER HEATED STEAM TEMP. : +/- 410 deg.C
• CHIMNEY TEMP. : 140 - 150 deg.C
• GREEN LIQUOR OUTLET : 1000 TPH/DAY
• STEAM PRESSURE O/L : 36kg/cm2
• STEAM TEMP. O/L : 410 – 415 deg.C
• STEAM FLOW O/L : 36 TPH.
IMPLEMENTATION
Level Control in a Reaction Vessel
PLC used in LEVEL
    CONTROL
PLC WIRING DIAGRAM
•The SIEMENS PLC specifications used for Level Control are :
•Software : STEP 7 LITE.
•MODEL : S7 300
•16 Digital Inputs
•4 Analog Inputs
•16 Digital Outputs
•9 Relay Outputs
•2 Analog Outputs
•Q1 : 24 V DC 0.5A MAX
•The Inputs and Outputs used in this project are Digital I/O „s only.
 I0.0    I0.1           I0.2    I0.3   Q0.1         Q0.2         M3.1        M3.2              Q0.0

        Q0.0                                                                                          Q0.4
        M3.0
                                                                                                      M3.0
                                                                                                      S
 I0.0    I0.1           I0.2    I0.3   Q0.0         Q0.2       M3.1         M3.2               Q0.1
                                                                                                            Q0.5

                                                                                                           M3.0
 I0.3   Q0.0            Q0.1   Q0.3     I0.0                                                          R
                                                                                      M0.1
M0.1
                                                                                                      M3.1
                                                                                                       S
 I0.0   M0.1                   M0.5    M3.2                                                     Q0.2

                                                                 T1
M0.1                                                           S_ODT                           M0.5
                                                           S            Q


                                              10s          TV

                                                           R

                       M0.5            I0.1         I0.0                            Q0.3

                      M3.2
                                                                                     M3.4

                Q0.3                                                                M3.1         M3.2
                                                                                                      S




 I0.0          I0.1                                                                   M3.2
                                                                                           R
                                                                                               M3.3
M3.3                                                                                 M3.1
                                                                                           R
M3.4
EXPLANATION:
•In Rung-1 the Switch I0.0 is active high and remaining I/Ps are kept active low. The
O/Ps of v/v-1 and Pump-1 shall be active high (Q0.0 & Q0.4), a latch of O/P v/v-1is
given to I0.1 because if Chemical-1crosses I0.1 then I0.1 will become active high and
O/Ps shall become active low. So, latch is provided for O/Ps to remain active high.
•In Rung-2 I0.0, I0.1 & I0.2 shall remain active high and O/Ps of v/v-2 and Pump-2
shall be active high (Q0.1 Q0.4) as Chemical-1reaches Medium level, at same instant
Chemical-2 shall flow to the vessel and Chemical-1 cease to flow.
•In Rung-3 as Chemical-2 reaches I0.3 Chemical-2 cease to flow, when I0.3 is active
high then memory O/P of Motor M0.1 is set as M3.1,latch of M0.1 make Motor to run
continuously .
•In Rung-4 I0.0,M0.1are kept active low and O/P of Timer M0.5,memory O/P of Drain
v/v M3.2 are active low. When M0.5 becomes high Motor stops.
•In Rung-5 M0.1acts as I/P to ON-Delay Timer, when Timer is activated Agitator mixes
both Chemicals.M0.5 shall be On after 10 seconds Delay.
•In Rung-6 M0.5 shall be active high making Drain v/v Q0.6 to open with the condition
I0.1 be active high.M3.2 is set memory of Drain v/v Q0.6 .
•Finally in Rung-7 when processed Chemical falls below I0.1 Drain v/v closes and this
process continues until Start/Stop Switch is pressed.
•In Rung-8 memory M3.3 &M3.4 are given to M3.1 to become reset because if motor
stops in middle then manually processed Chemical is drained , if power comes then
motor resets.
   WORKING :

•Initially the Tank shall be Empty.
•When the Start Push Button is pressed the Pump-1 and Inlet v/v-1will
be ON i.e., Chemical-1 shall flow from Pump-1 to Tank.
•Chemical-1 reaches Minimum/Low Level then it reaches Medium
Level.
•As the Mid Level is reached Chemical-1 stops flowing from Pump-1
and Chemical-2 is supplied by Pump-2 via Inlet v/v-2.
•When Maximum/High Level is reached by Chemical -2 ,Pump-2 cease
to supply Chemical-2.
•Then Motor shall be ON for specified time for mixing of both the
Chemicals with Agitator that is connected to Motor.
•When Motor Stops the Outlet v/v will drain the processed Chemical
mixture Outside.
•This process continues until Stop Push Button is pressed.
APPLICATIONS :
•Used in Bottling plants.
•Used in Chemical Industries like Fertilizers, Drugs.
•Used in Paper, Cement Industries .
 Conclusion:-
• The main theme of this Study project is Purging the
  Furnace at initial stage and activating the Emergency Trip
  and Drain valves during abnormal conditions while
  continuous running of process.

• This project can be used for better functioning of Boiler
  plant without any malfunctions by continuously
  monitoring the Industrial parameters and protecting the
  Boiler from destruction.
• PLC requires hardwiring only once and if there is any
  change in wiring , we can easily change it.
• Recovery department
• Power block department
• INSTRUMENTATION department
• JKPM Management



                               50
NO BOILER    AUXILLIARY                                   HOTV   AUXILLIARY PURGE              PURGE
TRIP         FUEL TRIP                                    CLOSED FUEL TRIP  COMPLETE           READY

   112             3065         2301    2302       2303    3043      160       368                557



              3066


SA/TA FAN   AIR     PA FAN FURNACE       FURNACE   DRUM            DRUM        ID FAN   ID FAN
RUNNING     FLOW    RUNNIN PRESSURE      PRESSURE LEVEL            LEVEL       START    RUNNING
            >30%    G      VERY LOW      VERY HIGH VERY LOW        VERY HIGH   PERMIT


   3051      3048     3053      3032        3033          3049    3050         115      3052         2301




 B-1                B-2          B-3               B-4                                   B1-4
 SCANNER            SCANNER      SCANNER           SCANNER                               SCANNER
 SHOW FILM          SHOW FILM    SHOW FILM         SHOW FILM                             SHOW FILM

                                                                                           2302
   3002             3007         3018              3023



 B-1 HOBV           B-2 HOBV     B-3 HOBV          B-4 HOBV                              B1-4 HOBV
 CLOSED             CLOSED       CLOSED            CLOSED                                CLOSED



   3001             3006         3017              3022                                    2303
Authorised By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
Engineeringpapers.blogspot.com
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