BMS SYSTEM OF
BOILER USING
PLC LADDER LOGIC
Authorised By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
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More Papers and Presentations available
on above site
ABSTRACT
Dust
Chipper House
White Liquor
Digestor
Weak
Black
Liquor
Washing /
Screening
Oxygen
Generation Plant
Chemical
Recovery Boiler
Evaporator
Steam
Oxygen
Delignification
Turbo Generator
Set
Unbleached Pulp
Storage
Chlorine Dioxide
Plant
Coal Handling
Plant
Causticizing Plant
DG Set
Grid Power
Coal Fired
Boilers
Steam
Process Plants
Bleaching
(CD + EOP +D)
Bleached Pulp
Storage
Steam
Stock Preparation
Coating
Plant
Paper Machines
Rewinders
Rewinders
Cutters
Cutters
Finishing House
Sales Godown
Wills Cutter
Market
BAMBOO
&
WOOD
WHITE LIQUOR
Pulp to Paper
Process
STEAM
WBL :16-18%
EVAPORATOR
LIME
CBL :55%-65%
WWL
STEAM
SMELT
RECOVERY
BOILER
G/L
RECAUSTICIZING STEAM
AREA
INTRODUCTI
ON
SUPER HEATER
FURNACE
PULP
MILL
FLUE GAS
TO CHIMNEY
FLUE GAS
ESP
WHITE
LIQUOR
SMELT
DUST
MUD
DISSOLVER
TANK
87-95 DEG.C
WBL
STORAGE
TANKS
G/L
PUMP
EVAPORATORS
WWL
SALT
CAKE
MIXING TANK
CAUSTICIZING
PLANT
THICK
BLACK LIQUOR
CBL
STORAGE TANKS
60-65 DEG.C
SECONDARY
HEATER
118 DEG.C
INDIRECT
HEATER
112 DEG.C
HBL
102 DEG.C
ID
FAN
BMS SECTION
SUPER HEATED/ DRY STEAM to TURBINE
SATURATED STEAM
SUPER HEATER
S
T
E
A
M
STEAM
DRUM
FLUE
GAS
ESP
PLATES
ID
FAN
FLUE
GAS
HBL
pump
SCMT
S
T
E
A
M
HAMMERS
FLUE
GAS
DUST
ESP ASH
TANK
pump
DAY
OIL
TANK
SA /
TA
FA
N
FEED WATER
PUMP
PA
FA
N
FIRING
ZONE
MUD
DRUM
IGNITOR
SPOUT
TANK
SMELT
ECONOMIZERS
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
R ON
BURNE
R
OFF
OIL GUN
ENGAGE
D
HEA
IGNITOR
ADVANCED
HEA
IGNITOR
RETRACTE
D
ATOMISING
V/V
OPENED
ATOMISING
V/V
CLOSED
BURNER
V/V
OPENED
BURNER
V/V
CLOSED
SCAVENGE
V/V
OPENED
SCAVENG
E
V/V
CLOSED
FLAME
FLAME SCANNER
SCANNER
SHOWS NO
SHOWS FLAME
FLAME
BURNE
R ON
BURNE
R
OFF
OIL GUN
ENGAGE
D
HEA
IGNITOR
ADVANCED
HEA
IGNITOR
RETRACTE
D
ATOMISING
V/V
OPENED
ATOMISING
V/V
CLOSED
BURNER
V/V
OPENED
BURNER
V/V
CLOSED
SCAVENGE
V/V
OPENED
SCAVENG
E
V/V
CLOSED
FLAME
FLAME SCANNER
SCANNER
SHOWS NO
SHOWS FLAME
FLAME
BURNE
R ON
BURNE
R
OFF
OIL GUN
ENGAGE
D
HEA
IGNITOR
ADVANCED
HEA
IGNITOR
RETRACTE
D
ATOMISING
V/V
OPENED
ATOMISING
V/V
CLOSED
BURNER
V/V
OPENED
BURNER
V/V
CLOSED
SCAVENGE
V/V
OPENED
SCAVENG
E
V/V
CLOSED
FLAME
FLAME SCANNER
SCANNER
SHOWS NO
SHOWS FLAME
FLAME
BURNE
R ON
BURNE
R
OFF
OIL GUN
ENGAGE
D
HEA
IGNITOR
ADVANCED
HEA
IGNITOR
RETRACTE
D
ATOMISING
V/V
OPENED
ATOMISING
V/V
CLOSED
BURNER
V/V
OPENED
BURNER
V/V
CLOSED
SCAVENGE
V/V
OPENED
SCAVENG
E
V/V
CLOSED
FLAME
FLAME SCANNER
SCANNER
SHOWS NO
SHOWS FLAME
FLAME
BURNER
2
BURNER
3
BURNER
4
BOILER
EMERGENCY
TRIP
EMERGENCY
DRAIN & TRIP
AUXILIARY
FUEL TRIP
PUSH
BUTTON
BOILER
TRIP
NO
BOILER
TRIP
ID
FAN
STAR
T
PER
MIT
AUXILIARY
FUEL TRIP
PUSH
BUTTON
SA/TA
FAN
STAR
T
PERM
IT
HO
PRESS
URE
LOW
LAM
P
TES
T
PA FAN
START
PERMIT
HO
TEMPE
RATUR
E
LOW
BLACK
LIQUOR
PUMP
START
PERMIT
OPE
N
HOT
V
SA/TA
FAN
RUNNIN
G
ID FAN
RUNNING
PRECIPITA
TOR
OUTLET
TEMP.
>270
DEG.C
CLOS
E
HOTV
EMERGENCY
DRAIN &
TRIP NOT
ACTIVATED
AUXILIA
RY
FUEL
TRIP
PRECIPITAT
OR
OUTLET
TEMP.
<270 DEG.C
OPE
N
HOR
V
FEED
WATER
SHUTOFF
VALVE
CLOSED
CLOS
E
HORV
START
PURGE
PUSH
BUTTO
N
PURGE
READY
ALL
SCANNE
R
SHOW
NO
FLAME
STAR
T
SCAN
NER
FAN-A
PURGE
IN
PROGR
ESS
AIR
FLOW
<30%
STOP
SCANNE
R
FAN-A
AIR
FLOW
<30%
PURGE
COMPL
ETE
ALL
EMERGEN
CY DRAIN
V/V S
CLOSED
DRUM
LEVEL
VERY
LOW
START
SCANNE
R
FAN-B
DRUM
LEVEL
VERY
HIGH
STOP
SCANN
ER
FAN-B
ATOMIS
ING
STEAM
PRESS
URE
LOW
FURNA
CE
PRESS
URE
VERY
LOW
ATOMISI
NG
STEAM
PRESSU
RE HIGH
FURNAC
E
PRESSU
RE
VERY
HIGH
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.
STEAM
DAY
FURNACE
SCAVENGE V/V
OIL
TANK
HOBV
HEATE
R
FURNACE OIL
PUMP
HORV
PRESSURE HOTV PRESSURE
3 WAY
CONTROL V/V
CONTROL V/V
V/V
8.0 Kg/cm2
15.0 Kg/cm2
OIL
ESP
CBL
TANK
ESP DUST
ESP
ASH
TANK
SCMT
CBL
PUMP
ESP ASH
TANK
LEVEL
CONTROL
V/V
Na2SO4
ASH
PUMP
PRESSUR
E
CONTROL
V/V
HBL
102 DEG.C
HBL
PUMP
INDIRE
CT
HEATE
R
DIRE
CT
HEAT
ER
112 DEG.C
FLOW
METE
R
118 DEG.C
FURNA
CE
BOILER TRIP
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 +4W.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.
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).
LADDER LOGICS
NO BOILER
TRIP
112
AUXILLIARY
FUEL TRIP
3065
HOTV
CLOSED
2301
2302
2303
3043
AUXILLIARY
FUEL TRIP
160
PURGE
COMPLETE
368
PURGE
READY
557
3066
SA/TA FAN
RUNNING
3051
3048
3053
FURNACE
PRESSURE VERY
LOW
3032
FURNACE
DRUM LEVEL
PRESSURE VERY VERY LOW
HIGH
3033
3049
DRUM LEVEL
VERY HIGH
3050
115
3052
2301
B-1 SCANNER
SHOW FILM
3002
B-2 SCANNER
SHOW FILM
B-3 SCANNER
SHOW FILM
B-4 SCANNER
SHOW FILM
3007
3018
3023
B1-4 SCANNER
SHOW FILM
2302
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
CLOSED
3001
B-2 HOBV
CLOSED
B-3 HOBV
CLOSED
B-4 HOBV
CLOSED
3006
3017
3022
B1-4 HOBV
CLOSED
2303
During Purge Ready initially the Furnace is Purged with fresh Air. So,
the Header Oil Burner v/vs B1-B4 should be closed.
INDUSTRIALSPECIFICATIONS
IMPLEMENTATION
PLC used in
LEVEL CONTROL
PLC WIRING
DIAGRAM
I0.0
I0.1
I0.2
I0.3
Q0.1
Q0.2
M3.2
M3.1
Q0.0
Q0.0
Q0.4
M3.0
I0.0
M3.0
I0.2
I0.1
I0.3
Q0.0
Q0.2
M3.1
M3.2
Q0.1
Q0.5
I0.3
Q0.0
Q0.1
Q0.3
I0.0
M0.1
M0.1
M3.0
M3.1
S
I0.0
M0.1
M0.5
M3.2
Q0.2
T1
M0.1
M0.5
S_ODT
S
TV
10s
M0.5
M3.2
Q0.3
I0.0
I0.1
I0.1
I0.0
Q0.3
M3.4
M3.1
M3.1
R
M3.4
M3.2
R
M3.3
M3.2
M3.3
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
TRIP
AUXILLIAR
Y FUEL
TRIP
112
306
5
230
1
230
2
230
3
304
3
160
PURGE
READY
368
557
306
6
SA/TA FAN
RUNNING
AIR
FLOW
>30%
305
1
B-1
SCANNER
SHOW FILM
3002
B-1 HOBV
CLOSED
3001
PA FAN
RUNNIN
G
FURNACE
PRESSURE
VERY LOW
3048 3053
3032
FURNACE
PRESSURE
VERY HIGH
3033
DRUM
LEVEL
VERY LOW
DRUM
LEVEL
VERY HIGH
3049 3050
B-2
SCANNER
SHOW FILM
B-3
SCANNER
SHOW FILM
B-4
SCANNER
SHOW FILM
300
7
301
8
3023
B-2 HOBV
CLOSED
B-3 HOBV
CLOSED
B-4 HOBV
CLOSED
300
6
301
7
3022
ID FAN
START
PERMIT
ID FAN
RUNNING
115
3052
2301
B1-4
SCANNER
SHOW FILM
2302
B1-4 HOBV
CLOSED
2303
Authorised By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
Engineeringpapers.blogspot.com
More Papers and Presentations available on