With the rapid development of industries, it has become essential for process plants to operate with precision to ensure the manufacturing of high-quality products. Efficiency and reliability have always been a priority in the case of industrial boilers. Yet, there is a considerable difference between the direct and indirect efficiency in boilers due to various losses occurring during operation. An interesting fact to note is that the boiler efficiency is usually rated between 73% and 77%, but the efficiency achieved ranges between 50% and 55%. The ideal solution to retain maximum efficiency and to bridge the gap between direct and indirect efficiency is Boiler automation.
Boiler Automation:
Boiler operations in process plants are generally monitored and handled by the plant personnel. Operations such as fuel feeding, maintaining the boiler accessories, etc., if performed manually may cause errors and loss of efficiency. For instance, while feeding fuel in the boiler, it must be assured that it is neither overfeed nor underfeed, leading to unburned fuels, improper combustion, and overall reduced efficiency of the boiler.
Boiler automation has been introduced in many industries that have witnessed a remarkable increase in efficiency and productivity. With the aid of sensors, boiler automation alerts the concerned plant manager, thereby reducing the chances of manual error.
Role of Boiler Automation:
Boiler Automation instantly alerts the operators of any practice that may lead to reduced efficiency with the help of sensors. It results in preventing the operations or errors that may cause losses. Here are some of the examples that can be avoided with boiler automation alerts,
- Adjustment of ID Fan damper to ensure an appropriate amount of air is provided to the furnace to keep stack losses at a minimum
- Uniform fuel feeding on fuel bed to avoid overfeeding in some sections that may result in unburned fuels and incomplete combustion
- Cleaning of boiler tubes to prevent the formation of soot layer that would reduce the heat transfer rate
- Improving water quality to ensure reduction in blowdown losses that consequently increases the boiler efficiency
- Closing of feed door as it is neglected and remains open in manual operations. It causes the ambient air of room temperature to enter the furnace that gets released carrying heat, eventually causing stack losses.
The two main components of a Boiler automation system are PLC or Programmable Logic Controller and SCADA or Supervisory Control and Data Acquisition.
Programmable Logic Controller (PLC):
Programmable Logic Controller, simply known as PLC is a computer system that is designed for operation and control in an industrial setting. PLC consists of CPU, memory, inputs and outputs, and software (relevant to industrial operation) and performs continuously as per the requirement of the processing operations. PLC operates industrial functions like manufacturing the assembling line in the process plant, waste management, etc.
Working of PLC:
The primary objective of PLC systems is scanning that includes the following process:
- Cycling and monitoring of time by the operating system
- CPU reads the input module data and checks the status of the inputs
- CPU begins to execute the application program
- Internal Diagnosis and Communication Tasks are performed by CPU
- Writing of data in the output module based on program results
Applications of PLC:
Programmable Logic Controller has a wide range of applications in various industries. Some of them include:
- Paper and Packaging Industry
- Cement Industry
- Glass Industry
- Process Automation Plants
- Thermal Power Plants
Supervisory Control and Data Acquisition (SCADA):
SCADA stands for Supervisory Control and Data Acquisition is a process control system that facilitates high-level supervision and control by using computers, network data communications, and Human Machine Interfaces (HMI). The system functions with other devices like Programmable Logic Controller (PLC) and Proportional–Integral–Derivative (PID) Controller. It manages the operation of industrial process plants and equipment.
SCADA Supervises the operations taking place in the process plant and Controls it by interacting with HMI. The information and data collected are analyzed in real-time and recorded. The SCADA system can function virtually, enabling the operator or manager to keep a track of the process from the control room. The system includes both hardware and software. The software is installed on the computer for analysis, and the hardware receives the input data that feeds it to the system for further assessment. It also includes a hard disk that records and stores the data which can be later printed if required.
Working of SCADA:
Supervisory Control and Data Acquisition system is a collection of hardware and software components that manages the functions of the processing plants. Some of the important operations of SCADA include:
- Monitoring and Gathering Data in real-time
- Recording information and data in a log file
- Communicating with control stations through Human Machine Interface (HMI)
- Controlling of manufacturing process virtually
- Storing of Information and Reports
Applications of SCADA:
- Power Generation, Transmission, and Distribution
- Manufacturing Units
- Steam Generation
- Process Operations in Industries like Food, Beverages, Oil, and Gas
- Wastewater and Sewage Management
Rakhoh Boilers has been manufacturing efficient steam boilers since its formation in 1983 while ensuring a balance between advancement and sustainability. We provide installation service of a boiler automation system for industrial boilers along with training to operate it. Boiler automation and control system is beneficial to process plants as it assures,
- High Efficiency
- Conservation of Natural Resources
- Boiler Safety
- High Productivity
- Longer Boiler Lifespan
Learn more about our products and services at www.rakhoh.com