The challenge: Idling gets you nowhere – and it can be costly. Standby
idling in traffic signals, traffic jams, parking at roadside to attend phone call
etc., wastes an enormous amount of fuel and money and generates needless
greenhouse gas emissions.
Engine idling by standby vehicles also contribute particulates and other
pollutants to the atmosphere which affect the health of people and the
environment. Small particulates from engines can enter and lodge in the
lungs of people and can aggravate asthma and cause lung damage.
Pollutants from automobiles contribute to acid rain, ozone formation, and
global climate change.
The solution: An advanced system aimed to reduce fuel consumption and
exhaust emissions by means of an automatic engine stop, while the vehicle is
stopped due to a traffic signal, traffic jam etc
Tuesday, June 2, 2009
ELECTRICITY FROM SOLID WASTES
Products used:
1. Temperature Monitoring Module (9211).
2. Pressure Monitoring Module (SCXI-1125).
3. Data Acquisition card (9172)
4. Analog input (9205).
5. Analog output (9263).
6. Digital input/output (9401)
7. LABVIEW 8.1 Express Software.
The Challenge:
The main objective of our project is mainly to meet the basic energy demands and
also to find an alternative solution for the solid waste management system.
The Solution:
Here we basically deal with the conversion of heat energy directly into electricity by the
thermo electric material. The concept in this conversion is that the domestic wastes are being
burnt with minimum effect on the environment. The process is monitored and controlled using
LABVIEW real time software.
Introduction:
The solid waste is collected from near by areas. After weighing, the waste goes to the
Waste-to-Energy plant. Here it is discharge into a huge bunker, and then incinerated over grates
round the clock. The heat generated is directly converted into electricity by the use of
thermoelectric material. The resultant electricity is supplied to local areas. The majority of
substance that does not burn is transformed into bottom ash that finds use in processes such as
road construction besides metal scrap recovery.
System Configuration:
In this system temperature monitoring module 9211 is interfaced with LABVIEW
software to detect and control the burning process. Pressure monitoring module is used to
maintain the pressure in the incinerator; if a pressure change takes place then the blower places
its part and brings it back to the required level. The level of raw material is checked periodically
with the help level indicator sensor.
System implementation:
The system can be divided into two modules
1. Monitoring module.
2. Controlling module.
The above two can be controlled by LABVIEW software.
1. Monitoring Module:
In this module we are monitoring three parameters – temperature, pressure, level of
raw material.
2. Controlling Module:
In order to maintain an uninterrupted operation of the unit the above parameters
are controlled in this module.
Conclusion:
Hence using this system we can rectify the ever lasting problem of solid waste
management and shortage of energy. This system is highly efficient productive and reduces the
pollution of the environment to the greatest extent.
1. Temperature Monitoring Module (9211).
2. Pressure Monitoring Module (SCXI-1125).
3. Data Acquisition card (9172)
4. Analog input (9205).
5. Analog output (9263).
6. Digital input/output (9401)
7. LABVIEW 8.1 Express Software.
The Challenge:
The main objective of our project is mainly to meet the basic energy demands and
also to find an alternative solution for the solid waste management system.
The Solution:
Here we basically deal with the conversion of heat energy directly into electricity by the
thermo electric material. The concept in this conversion is that the domestic wastes are being
burnt with minimum effect on the environment. The process is monitored and controlled using
LABVIEW real time software.
Introduction:
The solid waste is collected from near by areas. After weighing, the waste goes to the
Waste-to-Energy plant. Here it is discharge into a huge bunker, and then incinerated over grates
round the clock. The heat generated is directly converted into electricity by the use of
thermoelectric material. The resultant electricity is supplied to local areas. The majority of
substance that does not burn is transformed into bottom ash that finds use in processes such as
road construction besides metal scrap recovery.
System Configuration:
In this system temperature monitoring module 9211 is interfaced with LABVIEW
software to detect and control the burning process. Pressure monitoring module is used to
maintain the pressure in the incinerator; if a pressure change takes place then the blower places
its part and brings it back to the required level. The level of raw material is checked periodically
with the help level indicator sensor.
System implementation:
The system can be divided into two modules
1. Monitoring module.
2. Controlling module.
The above two can be controlled by LABVIEW software.
1. Monitoring Module:
In this module we are monitoring three parameters – temperature, pressure, level of
raw material.
2. Controlling Module:
In order to maintain an uninterrupted operation of the unit the above parameters
are controlled in this module.
Conclusion:
Hence using this system we can rectify the ever lasting problem of solid waste
management and shortage of energy. This system is highly efficient productive and reduces the
pollution of the environment to the greatest extent.
HY-WYRE TECHNOLOGY
INTRODUCTION
Cars are immensely complicated machine they have two basic elements the internal
combustion engine and mechanical and hydraulic linkages.
But in the Hy-wire car is that it doesn't have either of these two things. Instead of an
engine, it has a fuel cell stack, which powers an electric motor connected to the wheels.
Instead of mechanical and hydraulic linkages, it has a drive by wire system -- a computer
actually operates the components that move the wheels, activate the brakes and so on, and
based on input from an electronic controler
POWER
The "Hy" in Hy-wire stands for hydrogen, the standard fuel for a fuel cell system.
Like batteries, fuel cells have a negatively charged terminal and a positively charged
terminal that propel electrical charge through a circuit connected to each end. They are also
similar to batteries in that they generate electricity from a chemical reaction. But unlike a
battery, you can continually recharge a fuel cell by adding chemical fuel -- in this case,
hydrogen from an onboard storage tank and oxygen from the atmosphere.
The basic idea is to use a catalyst to split a hydrogen molecule (H2) into two H protons
(H+, positively charged single hydrogen atoms) and two electrons (e-). Oxygen on the
cathode (positively charged) side of the fuel cell draws H+ ions from the anode side
through a proton exchange membrane, but blocks the flow of electrons. The electrons
(which have a negative charge) are attracted to the protons (which have a positive charge)
on the other side of the membrane, but they have to move through the electrical circuit to
get there. The moving electrons make up the electrical current that powers the various loads
in the circuit, such as motors and the computer system. On the cathode side of the cell, the
hydrogen, oxygen and free electrons combine to form water (H2O), the system's only
emission product.
One fuel cell only puts out a little bit of power, so you need to combine many cells into a
stack to get much use out of the process. The fuel-cell stack in the Hy-wire is made up of
200 individual cells connected in series, which collectively provide 94 kilowatts of
continuous power and 129 kilowatts at peak power. The compact cell stack (it's about the
size of a PC tower) is kept cool by a conventional radiator system that's powered by the
fuel cells themselves.
CONTROL
The Hy-wire's "brain" is a central computer housed in the middle of the chassis. To
enable full computer control of each of the hy wire car the throttle, brake, and steering
actuation systems were converted to drive-by-wire .NI Compact RIO works as the car
computer, and Compact RIO FPGA modules acquire sensor information and generate
PWM actuator signals based on the control algorithms. It transmits a constant stream of
electronic command signals from the car controller to the central computer . . Compact
RIO Real-Time controllers receive sensor information from the FPGA and record all flight
data, also managing wireless Ethernet communications with the ground control station. The
Compact RIO FPGA receives and sends PWM actuators signals through the NI cRIO-9411
digital input module and the NI cRIO-9474 digital output module, respectively. The system
acquires status parameters such as battery voltage by means of the NI cRIO-9201 analog
input module,as well as feedback signals send from the computer to the controller. All of
these corresponding feedback signals, run through a National Instruments PXI-7344 fouraxis
motion control board This PXI motion control system is just one of three computers
that guide the vehicle. Instead of mirrors we use a dual lens camera for sense the images
infront of the vehicle at any given time .due to
NI PXI -8187, 2.5 GHZ , Pentium 4 m embended to rend the image
SYSTEM PERFORMANCE :
This system delivers DC voltage ranging from 125 to 200 volts, depending on the load in
the circuit. The motor controller boosts this up to 250 to 380 volts and converts it to AC
current to drive the three-phase electric motor that rotates the wheels .C
The electric motor's job is to apply torque to the front wheel axle to spin the two front
wheels. The control unit varies the speed of the car by increasing or decreasing the power
applied to the motor. When the controller applies maximum power from the fuel-cell stack,
the motor's rotor spins at 12,000 revolutions per minute, delivering a torque of 159 poundfeet.
A single-stage planetary gear, with a ratio of 8.67:1, steps up the torque to apply a
maximum of 1,375 pound-feet to each wheel. That's enough torque to move the 4,200-
pound (1,905-kg) car 100 miles per hour (161 kph) on a level road. Smaller electric motors
maneuver the wheels to steer the car, and electrically controlled brake calipers bring the car
to a stop.
CONCLUSION
The hywire technology car developed is highly flexible and reliable .while using the NI
hardware development platform – fast development, robustness, ease of use, a quick
learning curve, and good maintainability served the project . In future we will implement
the software& hard ware for improving the system .
The major problem in automobile manufacturing industries are
• Pollution
• Efficiency
• Heat dissipation
• Fuel consumption
Pollution
The combustion engine emits CO2 , CO, NO2 and other hazardous gases but ,the
concept car only emits H2O
Efficiency
The efficiency of this car is 30% more then other cars .
Heat dissipation
The combustion engine emits 125*c heat to atmosphere .but the car emits only
85*c . so the wear & tear losses may be reduced
Fuel consumption
Nowadays the petroleum by products &Electricity are getting reduced .so in
this car we using H2
Cars are immensely complicated machine they have two basic elements the internal
combustion engine and mechanical and hydraulic linkages.
But in the Hy-wire car is that it doesn't have either of these two things. Instead of an
engine, it has a fuel cell stack, which powers an electric motor connected to the wheels.
Instead of mechanical and hydraulic linkages, it has a drive by wire system -- a computer
actually operates the components that move the wheels, activate the brakes and so on, and
based on input from an electronic controler
POWER
The "Hy" in Hy-wire stands for hydrogen, the standard fuel for a fuel cell system.
Like batteries, fuel cells have a negatively charged terminal and a positively charged
terminal that propel electrical charge through a circuit connected to each end. They are also
similar to batteries in that they generate electricity from a chemical reaction. But unlike a
battery, you can continually recharge a fuel cell by adding chemical fuel -- in this case,
hydrogen from an onboard storage tank and oxygen from the atmosphere.
The basic idea is to use a catalyst to split a hydrogen molecule (H2) into two H protons
(H+, positively charged single hydrogen atoms) and two electrons (e-). Oxygen on the
cathode (positively charged) side of the fuel cell draws H+ ions from the anode side
through a proton exchange membrane, but blocks the flow of electrons. The electrons
(which have a negative charge) are attracted to the protons (which have a positive charge)
on the other side of the membrane, but they have to move through the electrical circuit to
get there. The moving electrons make up the electrical current that powers the various loads
in the circuit, such as motors and the computer system. On the cathode side of the cell, the
hydrogen, oxygen and free electrons combine to form water (H2O), the system's only
emission product.
One fuel cell only puts out a little bit of power, so you need to combine many cells into a
stack to get much use out of the process. The fuel-cell stack in the Hy-wire is made up of
200 individual cells connected in series, which collectively provide 94 kilowatts of
continuous power and 129 kilowatts at peak power. The compact cell stack (it's about the
size of a PC tower) is kept cool by a conventional radiator system that's powered by the
fuel cells themselves.
CONTROL
The Hy-wire's "brain" is a central computer housed in the middle of the chassis. To
enable full computer control of each of the hy wire car the throttle, brake, and steering
actuation systems were converted to drive-by-wire .NI Compact RIO works as the car
computer, and Compact RIO FPGA modules acquire sensor information and generate
PWM actuator signals based on the control algorithms. It transmits a constant stream of
electronic command signals from the car controller to the central computer . . Compact
RIO Real-Time controllers receive sensor information from the FPGA and record all flight
data, also managing wireless Ethernet communications with the ground control station. The
Compact RIO FPGA receives and sends PWM actuators signals through the NI cRIO-9411
digital input module and the NI cRIO-9474 digital output module, respectively. The system
acquires status parameters such as battery voltage by means of the NI cRIO-9201 analog
input module,as well as feedback signals send from the computer to the controller. All of
these corresponding feedback signals, run through a National Instruments PXI-7344 fouraxis
motion control board This PXI motion control system is just one of three computers
that guide the vehicle. Instead of mirrors we use a dual lens camera for sense the images
infront of the vehicle at any given time .due to
NI PXI -8187, 2.5 GHZ , Pentium 4 m embended to rend the image
SYSTEM PERFORMANCE :
This system delivers DC voltage ranging from 125 to 200 volts, depending on the load in
the circuit. The motor controller boosts this up to 250 to 380 volts and converts it to AC
current to drive the three-phase electric motor that rotates the wheels .C
The electric motor's job is to apply torque to the front wheel axle to spin the two front
wheels. The control unit varies the speed of the car by increasing or decreasing the power
applied to the motor. When the controller applies maximum power from the fuel-cell stack,
the motor's rotor spins at 12,000 revolutions per minute, delivering a torque of 159 poundfeet.
A single-stage planetary gear, with a ratio of 8.67:1, steps up the torque to apply a
maximum of 1,375 pound-feet to each wheel. That's enough torque to move the 4,200-
pound (1,905-kg) car 100 miles per hour (161 kph) on a level road. Smaller electric motors
maneuver the wheels to steer the car, and electrically controlled brake calipers bring the car
to a stop.
CONCLUSION
The hywire technology car developed is highly flexible and reliable .while using the NI
hardware development platform – fast development, robustness, ease of use, a quick
learning curve, and good maintainability served the project . In future we will implement
the software& hard ware for improving the system .
The major problem in automobile manufacturing industries are
• Pollution
• Efficiency
• Heat dissipation
• Fuel consumption
Pollution
The combustion engine emits CO2 , CO, NO2 and other hazardous gases but ,the
concept car only emits H2O
Efficiency
The efficiency of this car is 30% more then other cars .
Heat dissipation
The combustion engine emits 125*c heat to atmosphere .but the car emits only
85*c . so the wear & tear losses may be reduced
Fuel consumption
Nowadays the petroleum by products &Electricity are getting reduced .so in
this car we using H2
POWER PLANT BOILER FIRING CONTROL AND DATA ACQUISITION
The boiler protection and burner management system are dedicated for boiler
furnace safety and controlling fuel burning equipment. The highest possible safety and
reliability are among the most important requirements in power plant operation. Fully
integrated, automation and safety functions enable the possibility to bring all the
necessary information to the operator. The operator is provided with informative displays
that allow the operator to avoid unsafe conditions. The cause of a process failure is
indicated in a clear, visual manner .Here using Lab VIEW , a clear and user friendly way
of controlling boiler firing system is proposed.
I.INTRODUCTION
A boiler is an isolated pressurized vessel in which water or other fluid gets
transformed into high quality steam. The steam or hot fluid is then circulated out of the
boiler for various process as well as heating applications. Thermal input to the boiler is
through combustion of fuels such as wood, coal, oil, natural gas etc. Resistance or
immersion type heating elements are usually found in electric boilers. Nuclear fission is
also recommendable as heat source for steam generation.
In this project, the boiler used is a gas fired one in which natural gas is the fuel.
The sequence of setting up and turning down the burner is termed as firing sequence.
More technically, the safest way of starting and stopping the boiler burner is firing
sequence. Interlocking of the burner firing sequence was accomplished through hard
wired relay logics which were later replaced by PLC.
Programmable Logic Controllers are used to establish a control over the firing
process and LabVIEW software for the analysis of sequential operation. With LabVIEW
the sequence of operation can be prototyped and simulated, facilitating flexible
modification provisions when dealing with real model. DAQ card ensure acquisition of
the external inputs, PLC establish control over the process and ultimately process
monitoring is through LabVIEW.
II.BOILER PROTECTION AND BURNER MANAGEMENT SYSTEM
Key Benefits
i. Prevent firing unless a satisfactory furnace purge has first been completed.
ii. Prohibit start-up of the equipment unless certain permissive interlocks have first
been completed.
iii. Monitor and control the correct component sequencing during start-up and shutdown
of the equipment.
iv. Conditionally allow the continued operation of the equipment only while certain
safety interlocks remaining satisfied.
v. Provide component condition feedback to the operator and, if so equipped, to the
plant control systems and/or data loggers.
Provide automatic supervision when the equipment is in service and provide
means to make a Master Fuel Trip (MFT) should certain unacceptable firing conditions
occur
Power Plant Boiler
III.POWER PLANT BOILER FIRING SEQUENCE
Purging process
Because many boilers are fire-operated by natural gas, diesel or fuel oil, special
precautions need to be taken. Boiler operators should ensure that the fuel system,
including valves, lines, and tanks, is operating properly with no leaks. To prevent furnace
explosions, it is imperative that boiler operators purge the boiler before ignition of the
burner.
Fuel line Charging:
• The interlocks for starting the process is checked and fuel line is charged
• The pilot line is charged manually first along with igniter.
• After some time period the main line is charged automatically and pilot line is deenergized.
The process is repeated for all the other three corners
IV. INTERLOCKS
1. Once all the above permissives are satisfied "PURGE READY" Indication will
be illuminated.
2. Now, the operator would press "PURGE START" Push Button
3. With all above interlocks healthy and with Purge Start Push Button Pressed,
"PURGEIN-PROGRESS" indication lamp will be illuminated for 5 minutes.
System will continuously monitor all above mentioned conditions & incase of
failure of any one of above mentioned conditions, system will restart from
"Purge Ready" cycle.
4. After completion of Purge Timer (5 min), "PURGE COMPLETE" lamp will be
illuminated and "PURGE IN PROGRESS" Lamp will be de-illuminated.
5. Also with ‘Purge complete’ indication, NG main line and pilot main line valves
will be energized to open
6. If after 10 minutes of purge complete, operator will not initiate "Burner Start"
sequence, then "PURGE COMPLETE" lamp will be deilluminated and all NG
main line valves and pilot main line valves will be de-energized. Operator has to
re-start the process from the 'Purge Ready' cycle.
Burner Starting Sequence
7. Operator has to select burner and press Burner Start PB
8. "PURGE COMPLETE" Lamps will be de-illuminated as soon as the "Burner
Start” command is initiated.
9. Ignition Transformer of selected burners will be energized for 10 seconds and
"Burner-X Ignition ON" indication will be illuminated.
10. Ignition Transformer of selected burners will be energized for 10 seconds and
"Burner-X Ignition ON" indication will be illuminated.
11. Along with Ignition transformer, Pilot solenoid valves of the selected burner will
be energized to open. "Pilot Burner-X ON" indication will be illuminated.
12. If within ignition period flame scanners will not sense the flame than after
ignition period with ignition transformer, selected burner's pilot valves will be deenergized
&Operator has to re-start the system from the "Purge Ready" Cycle (If
no other burners in operation).
13. With flame sense by the scanner during ignition period, "Burner-X FLAME ON"
indication will be illuminated.
14. If within ignition period both flame scanners will not sense the flame (minimum
one scanner has to pickup the flame) than after ignition period with ignition
transformer, selected burner's pilot valves will be de-energized
15. With 10 seconds of Ignition period over and with Pilot flame established and
proved, selected Burner's SSOV will be energized to Open and "Burner-X ON"
indication will be illuminated. Selected Burner’s Pilot valve remain energize for
another 20 seconds to support the main flame. After ignition period at any time if
the flame fail, then all the valves of the respective burner will be de-energized and
"Burner-X Flame Failure" Annunciation will be illuminated. After pilot burner
de-energized, both the scanner should have sense the flame.
16. After successfully establishing first burner, operator has to establish other three
burners with the above mentioned procedure.
Interlocks
V.SYSTEMS
Programmable Logic Controller
PLC was invented in 1968 as a substitute for hardwired relay panels. According to
NEMA PLC is digitally operating electronic apparatus which uses a programmable
memory for the internal storage of instructions by implementing specific functions such
as logic sequencing, timing, counting, and arithmetic to control, through digital or analog
input/output modules, various types of machines or processes. The digital computer
which is used to perform the functions of a programmable controller is considered to be
within this scope. Excluded are drum and other similar mechanical sequencing
controllers.
Lab VIEW
Lab VIEW stands for Laboratory Virtual Instrument Engineering Workbench All
measurement devices are basically composed of the same building blocks with different
kinds of processing behind them
i. Analog Input
ii. Analog Output
iii. Digital Input
PURGE
PERMISSIVES
PURGE
START
PURGE
COMPLETE
IGNITOR
START
FIRE
OK
PILOT LINE
ENERGIZE
D
NG MAIN LINE
ENERGISED
&PILOT LINE DE
ENERGISEED
SAME TO
CORNER
2,3,4
AFTER 5
MIN WITHIN
10 MIN
WITHIN
10 MIN
AFTER
10 MIN
AFTER
10 MIN
AFTER 10
MIN IF FIRE
NOT OK
OK
PURGE
PROGRESS
iv. Digital Output
v. Counters & Timer
All measurement instruments can be defined by linking the basic blocks with processing
Virtual Instrument is a set of software that links together basic hardware elements to form
different instrument A VI can be the simplest form of processing to a very complex set of
sequences.
Inputs
The real world field inputs are replaced by hardware switches. The hardware
switches will give output of the real world input which are digital in nature. The purge
start permissives are replaced with a push to ON, push to OFF switches. Purge start is
given from a push to ON switch .Fire contact ON is replaced with push to ON, push to
OFF switch. Corner Fire ON (starting a corner firing) and AUTO ON is given from push
to ON switch.
Control Unit
Two PLC units are used for controlling the process. The inputs for the PLC’s are
given from the hardware switches. The 24v DC for the inputs is taken from the OMRON
PLC. The OM RON PLC is controlling the purge process and necessary interlocking for
the firing process and two corner firing. Siemens PLC controls the rest two corners firing,
once initial condition is OK .Auto firing controlled by both PLC’s for their respective
corners.
Output
The final output (real world final control element) of the process is analyzed using
LabVIEW model of the real process. The outputs from the system control unit that is the
PLC’s are given as input for the system model in LabVIEW .The 5v DC from DAQ 6251
is given to the PLC output contacts (potential free contacts). The real world burner corner
is modeled using LabVIEW and using the inputs through DAQ 6251, the system
operation is analysed.
.Project Setup
Project Front Panel
VI.CONCLUSION
This method adds flexibility in controlling the firing sequence of power plant
boiler efficiently which is better than the existing system in economic considerations of
maintenance. The provision made for firing control based on load requirement helps to
control the firing method in an adaptable way. Lab VIEW software and DAQ cards of
National Instruments facilitate live analysis and control of the firing operation .With this
system, the economic and time losses due to undesired tripping and malfunctioning of
process equipments are minimized.
furnace safety and controlling fuel burning equipment. The highest possible safety and
reliability are among the most important requirements in power plant operation. Fully
integrated, automation and safety functions enable the possibility to bring all the
necessary information to the operator. The operator is provided with informative displays
that allow the operator to avoid unsafe conditions. The cause of a process failure is
indicated in a clear, visual manner .Here using Lab VIEW , a clear and user friendly way
of controlling boiler firing system is proposed.
I.INTRODUCTION
A boiler is an isolated pressurized vessel in which water or other fluid gets
transformed into high quality steam. The steam or hot fluid is then circulated out of the
boiler for various process as well as heating applications. Thermal input to the boiler is
through combustion of fuels such as wood, coal, oil, natural gas etc. Resistance or
immersion type heating elements are usually found in electric boilers. Nuclear fission is
also recommendable as heat source for steam generation.
In this project, the boiler used is a gas fired one in which natural gas is the fuel.
The sequence of setting up and turning down the burner is termed as firing sequence.
More technically, the safest way of starting and stopping the boiler burner is firing
sequence. Interlocking of the burner firing sequence was accomplished through hard
wired relay logics which were later replaced by PLC.
Programmable Logic Controllers are used to establish a control over the firing
process and LabVIEW software for the analysis of sequential operation. With LabVIEW
the sequence of operation can be prototyped and simulated, facilitating flexible
modification provisions when dealing with real model. DAQ card ensure acquisition of
the external inputs, PLC establish control over the process and ultimately process
monitoring is through LabVIEW.
II.BOILER PROTECTION AND BURNER MANAGEMENT SYSTEM
Key Benefits
i. Prevent firing unless a satisfactory furnace purge has first been completed.
ii. Prohibit start-up of the equipment unless certain permissive interlocks have first
been completed.
iii. Monitor and control the correct component sequencing during start-up and shutdown
of the equipment.
iv. Conditionally allow the continued operation of the equipment only while certain
safety interlocks remaining satisfied.
v. Provide component condition feedback to the operator and, if so equipped, to the
plant control systems and/or data loggers.
Provide automatic supervision when the equipment is in service and provide
means to make a Master Fuel Trip (MFT) should certain unacceptable firing conditions
occur
Power Plant Boiler
III.POWER PLANT BOILER FIRING SEQUENCE
Purging process
Because many boilers are fire-operated by natural gas, diesel or fuel oil, special
precautions need to be taken. Boiler operators should ensure that the fuel system,
including valves, lines, and tanks, is operating properly with no leaks. To prevent furnace
explosions, it is imperative that boiler operators purge the boiler before ignition of the
burner.
Fuel line Charging:
• The interlocks for starting the process is checked and fuel line is charged
• The pilot line is charged manually first along with igniter.
• After some time period the main line is charged automatically and pilot line is deenergized.
The process is repeated for all the other three corners
IV. INTERLOCKS
1. Once all the above permissives are satisfied "PURGE READY" Indication will
be illuminated.
2. Now, the operator would press "PURGE START" Push Button
3. With all above interlocks healthy and with Purge Start Push Button Pressed,
"PURGEIN-PROGRESS" indication lamp will be illuminated for 5 minutes.
System will continuously monitor all above mentioned conditions & incase of
failure of any one of above mentioned conditions, system will restart from
"Purge Ready" cycle.
4. After completion of Purge Timer (5 min), "PURGE COMPLETE" lamp will be
illuminated and "PURGE IN PROGRESS" Lamp will be de-illuminated.
5. Also with ‘Purge complete’ indication, NG main line and pilot main line valves
will be energized to open
6. If after 10 minutes of purge complete, operator will not initiate "Burner Start"
sequence, then "PURGE COMPLETE" lamp will be deilluminated and all NG
main line valves and pilot main line valves will be de-energized. Operator has to
re-start the process from the 'Purge Ready' cycle.
Burner Starting Sequence
7. Operator has to select burner and press Burner Start PB
8. "PURGE COMPLETE" Lamps will be de-illuminated as soon as the "Burner
Start” command is initiated.
9. Ignition Transformer of selected burners will be energized for 10 seconds and
"Burner-X Ignition ON" indication will be illuminated.
10. Ignition Transformer of selected burners will be energized for 10 seconds and
"Burner-X Ignition ON" indication will be illuminated.
11. Along with Ignition transformer, Pilot solenoid valves of the selected burner will
be energized to open. "Pilot Burner-X ON" indication will be illuminated.
12. If within ignition period flame scanners will not sense the flame than after
ignition period with ignition transformer, selected burner's pilot valves will be deenergized
&Operator has to re-start the system from the "Purge Ready" Cycle (If
no other burners in operation).
13. With flame sense by the scanner during ignition period, "Burner-X FLAME ON"
indication will be illuminated.
14. If within ignition period both flame scanners will not sense the flame (minimum
one scanner has to pickup the flame) than after ignition period with ignition
transformer, selected burner's pilot valves will be de-energized
15. With 10 seconds of Ignition period over and with Pilot flame established and
proved, selected Burner's SSOV will be energized to Open and "Burner-X ON"
indication will be illuminated. Selected Burner’s Pilot valve remain energize for
another 20 seconds to support the main flame. After ignition period at any time if
the flame fail, then all the valves of the respective burner will be de-energized and
"Burner-X Flame Failure" Annunciation will be illuminated. After pilot burner
de-energized, both the scanner should have sense the flame.
16. After successfully establishing first burner, operator has to establish other three
burners with the above mentioned procedure.
Interlocks
V.SYSTEMS
Programmable Logic Controller
PLC was invented in 1968 as a substitute for hardwired relay panels. According to
NEMA PLC is digitally operating electronic apparatus which uses a programmable
memory for the internal storage of instructions by implementing specific functions such
as logic sequencing, timing, counting, and arithmetic to control, through digital or analog
input/output modules, various types of machines or processes. The digital computer
which is used to perform the functions of a programmable controller is considered to be
within this scope. Excluded are drum and other similar mechanical sequencing
controllers.
Lab VIEW
Lab VIEW stands for Laboratory Virtual Instrument Engineering Workbench All
measurement devices are basically composed of the same building blocks with different
kinds of processing behind them
i. Analog Input
ii. Analog Output
iii. Digital Input
PURGE
PERMISSIVES
PURGE
START
PURGE
COMPLETE
IGNITOR
START
FIRE
OK
PILOT LINE
ENERGIZE
D
NG MAIN LINE
ENERGISED
&PILOT LINE DE
ENERGISEED
SAME TO
CORNER
2,3,4
AFTER 5
MIN WITHIN
10 MIN
WITHIN
10 MIN
AFTER
10 MIN
AFTER
10 MIN
AFTER 10
MIN IF FIRE
NOT OK
OK
PURGE
PROGRESS
iv. Digital Output
v. Counters & Timer
All measurement instruments can be defined by linking the basic blocks with processing
Virtual Instrument is a set of software that links together basic hardware elements to form
different instrument A VI can be the simplest form of processing to a very complex set of
sequences.
Inputs
The real world field inputs are replaced by hardware switches. The hardware
switches will give output of the real world input which are digital in nature. The purge
start permissives are replaced with a push to ON, push to OFF switches. Purge start is
given from a push to ON switch .Fire contact ON is replaced with push to ON, push to
OFF switch. Corner Fire ON (starting a corner firing) and AUTO ON is given from push
to ON switch.
Control Unit
Two PLC units are used for controlling the process. The inputs for the PLC’s are
given from the hardware switches. The 24v DC for the inputs is taken from the OMRON
PLC. The OM RON PLC is controlling the purge process and necessary interlocking for
the firing process and two corner firing. Siemens PLC controls the rest two corners firing,
once initial condition is OK .Auto firing controlled by both PLC’s for their respective
corners.
Output
The final output (real world final control element) of the process is analyzed using
LabVIEW model of the real process. The outputs from the system control unit that is the
PLC’s are given as input for the system model in LabVIEW .The 5v DC from DAQ 6251
is given to the PLC output contacts (potential free contacts). The real world burner corner
is modeled using LabVIEW and using the inputs through DAQ 6251, the system
operation is analysed.
.Project Setup
Project Front Panel
VI.CONCLUSION
This method adds flexibility in controlling the firing sequence of power plant
boiler efficiently which is better than the existing system in economic considerations of
maintenance. The provision made for firing control based on load requirement helps to
control the firing method in an adaptable way. Lab VIEW software and DAQ cards of
National Instruments facilitate live analysis and control of the firing operation .With this
system, the economic and time losses due to undesired tripping and malfunctioning of
process equipments are minimized.
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