Ijaiem 2013 04 25 069
Ijaiem 2013 04 25 069
Ijaiem 2013 04 25 069
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com Volume 2, Issue 4, April 2013 ISSN 2319 - 4847
Application of an online fuzzy logic remote condition monitoring on water tube boilersBabcock and Wilcox (British) and La Mont (French) boilers (Anonymous Company in Zimbabwe)
Mayahle Leanmark1, Mugwindiri Kumbirayi2 and Mushiri Tawanda3
1
Undergraduate Student, Department of Mechanical Engineering, University of Zimbabwe, P.O. Box MP167, Mt Pleasant, Harare, Zimbabwe
Postgraduate Coordinator, Department of Mechanical Engineering, University of Zimbabwe, P.O. Box MP167, Mt Pleasant, Harare, Zimbabwe
3
Mechanical Engineering Lecturer, Department of Mechanical Engineering, University of Zimbabwe, P.O. Box MP167, Mt Pleasant, Harare, Zimbabwe
ABSTRACT
A LaMont boiler is a type of forced circulation water-tube boiler in which the boiler water is circulated through an external pump through long closely spaced tubes of small diameter. The mechanical pump is employed in order to have an adequate and positive circulation in steam and hot water boilers. A water tube boiler is a type of boiler in which water circulates in tubes heated externally by the fire. Fuel is burned inside the furnace, creating hot gas which heats water in the steam-generating tubes. In smaller boilers, additional generating tubes are separate in the furnace, while larger utility boilers rely on the waterfilled tubes that make up the walls of the furnace to generate steam. Condition Based Maintenance using fuzzy logic was used to control the temperature and pressure entrance into the boiler. Any excess in the entry will have negative effects like corrosion of parts and also rupture of the boiler. The research here addresses this issue. Fuzzy logic was used with MATLAB software for the boiler to be controlled intelligently. Rules were generated and came up with a solution. The results predict that pressure should be maintained at between 450 850 psi and temperature should be monitored at 8000F for these types of boilers.
1. INTRODUCTION
Boiler feed pumps fail due to numerous reasons. These include eroded impellers, electric motor failure; worn out bearings, check valve failure etc. At this local power station after looking at the general performance information it is evident that poor water treatment and monitoring has contributed to some of the pump failure. The impellers and check valves are eroded due to corrosive minerals in the hard water. Failure of check valves has led to back flow of the superhot condensate from the boiler thereby causing cavitation. Bearings have been worn out due to contaminated oil or lubrication. The worn out bearings have led to the motor over heating resulting in motor failure. 1.1 CONDITION BASED MAINTENANCE AS A SUBSET OF RELIABILITY CENTRED MAINTENANCE The major reductions in routine operations and scheduling leads directly to large reductions in operations cost (Kiinigsmann 1996), htt://www.ct@consulting.com.au/MaintEng.htm. This is because equipment can revert to systemic failure even after maintenance has been carried out if due regard to maintenance instructions is not adhered to. Reliability Centred maintenance is much more than just another way to do maintenance. In a nutshell, it's a way of looking at system performance in terms of the impact of a failure and then mitigating those results by design, detection, or effective maintenance (Wheeler, 2007). RCM develops a comprehensive data base of maintenance requirements, skills required and stocks that should be held (Zhongwei, 2010). In addition, RCM also has an important role in overall system
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Figure 1 Change in maintenance philosophy: Condition-based maintenance (CBM), shortly described, is maintenance when need arises. This maintenance is performed after one or more indicators show that equipment is going to fail or that equipment performance is deteriorating. This concept is applicable to mission critical systems that incorporate active redundancy and fault reporting. It is also applicable to non-mission critical systems that lack redundancy and fault reporting. Condition-based maintenance was introduced to try to maintain the correct equipment at the right time. CBM is based on using real-time data to prioritize and optimize maintenance resources. Observing the state of the system is known as condition monitoring. Such a system will determine the equipment's health, and act only when maintenance is actually necessary. Developments in recent years have allowed extensive instrumentation of equipment, and together with better tools for analyzing condition data, the maintenance personnel of today are more than ever able to decide what is the right time to perform maintenance on some piece of equipment. Ideally condition-based maintenance will allow the maintenance personnel to do only the right things, minimizing spare parts cost, system downtime and time spent on maintenance.
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Figure 4 Drum-level control with a two-element module (http://www.plantservices.com/articles/2004/180.html). 7.3 Best way
Figure 5 Drum-level control with a three-element module (http://www.plantservices.com/articles/2004/180.html). Two-element drum-level control can best be applied to a single drum boiler if the feedwater is at a constant pressure. Two-element control (see Figure 4) includes the same level element used for the single-element configuration but has an added steam-flow element that provides a density-corrected mass flow-rate signal to control the feedwater flow. Two elements offer tighter control of drum level. The steam flow acts as a feed-forward signal to allow faster level
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9. METHODOLOGY
9.1 TWO FUZZY SETS PRESSURE, P AND TEMPERATURE, T Union of the two fuzzy sets is defined as the maximum of the two individual membership functions. This is called the maximum criterion, PuB = maximum (P, T)
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change in pressur e
Rules can now be written as below 1. 2. 3. 4. 5. 6. 7. IF ( change in temperature is positive) THEN ( change in rupture is high) IF (change in temperature is zero) THEN ( change in rupture is average) IF(change in temperature is negative) THEN ( change in rapture is high) IF (change in pressure is negative) THEN ( change in rupture is high) IF (change in pressure is zero) THEN (change in rupture is average) IF (change in pressure is positive) THEN (change in rupture is high) IF ( change in temperature is negative) AND ( change in pressure is negative THEN ( change in rupture is high) IF (change in temperature is zero ) AND (change in pressure is zero) THEN (change in rupture is average) IF (change in temperature is Positive AND ( change in pressure is negative) THEN ( change in rupture is high) IF (change in temperature is negative) AND (change in pressure is zero THEN ( change in rupture is "average")
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Figure 12 Surface viewer for the boiler control in temperature and pressure in 3D
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