BOILER AUTOMATION USING PROGRAMMABLE LOGIC CONTROLLER

INTRODUCTION

PLC applications are extensively used in industry to control and facilitate repetitive processes such as
manufacturing cell management, fly-by-wire control, or nuclear plant shutdown systems. One of these
applications is industrial automation which includes numerous automated processes. This again includes
automation of boiler which demands determination of certain physical parameters (viz. pressure,
temperature, etc.) & utilizing these parameters to make the boiler start-stop or function in any manner
we want, but automatically, without involvement of any personal.

PROJECT IN BRIEF

OBJECTIVE: Designing of a PLC controlled boiler for production of steam.

PROJECT AT A GLANCE:

SOFTWARE AND COMPONENTSUSED:

 KGL software (make LG)

 PLC module (make LG)
Motor
 Water reserve
 Closed air tight container
 Level sensor(Digital)
 Temperature sensor with current output(Analog)
 Pressure sensor(Analog)
 Solenoid valve(Digital)
The most common parameters that have to be controlled in the boiler are temperature, pressure, water
level. The controlling mechanism can be achieved by using microprocessor and microcontroller, PID
controller or using PLC. Programmable logic control (PLC) provides an easy and sophisticated method to
design automation in industry. It also provides easy trouble shooting method and flexibility to the
industry.

Generally an industry has an emergency stop button to stop the whole process instantly if any error
occurred during operation. The emergency stop buttons are normally closed type. To start the
mechanism a start button (normally open type) switch is used which is connected after stop button.
When start button is made ON the lower level sensor sense the water level below the lower level hence
it start the motor to pump the water in to the boiler. The pump runs till the water reaches the higher
level sensor. After that the pump stops running. The temperature sensor provides the temperature
information to the PLC. If the temp. is less then the preset value the heater starts after 5 sec of motor
OFF time. Temperature rises continuously and form water steam. The temp. should not rise beyond
tolerance level of boiler hence the temp. should rise up to certain limit and the heater should stop at
that moment. The temp. again decreases and if goes below preset value it start the heater. The above
process continues. The steam produce in the boiler exert a pressure on the boiler which is picked up by
the pressure sensor. If pressure reaches the preset value it make the valve open and steam with a
definite pressure goes out through the pipe. The preset value of the pressure should be calculated
carefully and it should not exceed maximum limit of boiler tolerance. This process result in decrease in
water level and if falls below the lower level sensor the motor starts during which the heater stops and
whole process repeats.
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FLOW CHART:

YES

YES

NO

NO

START

Is stop

button NC?

NO

Is start

button NO?

Is LLS NC?

Is HLS NC?

Is heater

timer NC?

START MOTOR

Is motor

coil NO?

NO

NO

STOP MOTOR AND

START MOTOR
TIMER

Is upper
temp. Reach

NO

YES

YES

NO

YES
4

Is temp less

then preset?

Is heater coil

made NO?

Is LLS switch

NO?

Heater memory coil is ON

Is motor

timer NC?

NO

YES

HEATER COIL IS

OFF

Is heater mem.

Coil NO?

NO

HEATER COIL IS on

NO

YES
YES

HEATER COIL IS OFF

AND TIMER IS ON

Is press. Reaches

presets?

OPEN THE VALVE

VALVE REMAIN CLOSED

NO

YES

STOP

NO

YES

YES

NO

DIFFERENTSECTIONS OF THE PROJECT: The project incorporates the requirement of a

physical PLC trainer kit which is responsible for collection of data from field sensors (within the boiler),
evaluate them & generate appropriate output for the boiler to operate in a specific desired procedure.
Initially, we divided our project into four sections viz.,power supply section, water

supply section, boiler (including sensors) section,process controlling section.

BoilerSection: Boiling container, sensors (presssure,temperature & level sensors) & a heater

assemble altogether to give rise to the boiler section.

ControllingSection: This section includes the PLC trainer kit which is responsible for data

collection from field sensors, evaluation of collected data & generation of appropriate output signals for
automatic actuation and termination of different peripherals incorporated in the overall system.
WaterSupplySection:Water supply to the boiler is ensured by a water pump whose actuation

& termination is controlled by the PLC trainer.

PowerSupplySection: This takes care of the power requirements for the whole project. This

mostly comprises of the circuits providing DC power for the field sensors and valves (solenoids).

APPLICATIONS: The main advantage of using PLCs is the drastic reduction in the

requirement of electrical components in terms of number of switches, relays, wiring, etc.the

applications of this project are solely the applications of a boiler i.e., production of steam and using it for
numerous processes like rotating the generator fins and hence producing power for commercial or
industrial purposes.

STAGES OF PROJECT DESIGN:

We divided the overall construction of the project in two stages. These are described as follows:

STAGE 1:

This stage basically focuses on:

(i)

Software design & simulation

(ii)

Hardware design

(A).Power supply &

(b) .Sensing unit

j Level Sensing Unit

j Temperature sensing unit

SOFTWAREDESIGN& SIMULATION

The software design and simulation part of the whole project is done by using the software ³KGL´. This
software is used to design the ladder diagram of the overall project simulation in order to study it`s
behaviour.The ladder design hence obtained is downloaded into the PLC CPU and thereby generating
appropriate output signals required for the simulation.

Features of KGL for Windows

KGL for Windows is the Programming and Debugging Tool for LG Master-KS er ies.

KGL for Windows has abundant Features as below.

1) Program Compatible between LG Master-KSeries.

A user can use the Program (*.PGM) created in LG Master-K Series for the Program created in other LG
Master-K Series As well. The Program, Parameter or Variable/Comment created inKGL-DOS or GSIKGL
can be also used inKGL forWindows.

2) PLCSystem Configuration by ProjectStructure

KGL for Windows manages the User-Defined Program as one Project including

Parameter and Variable/Comment. Also a user can save a Program (*.PRG), Parameter (*.PMT),
Variable (*.VAR) or Comment (*.CNT) respectively and the stored each File can be used for
other Project files.

3) User Friendly Interface

Easy and useful interface for Creating, Editing and Monitoring.

4) Online Editing

A Real Time Editing is available in online mode. The Program edited in the online

condition can be downloaded automatically without stopping PLC Hardware.

5) Monitoring the Information from PLC

A user can easily monitor PLC status such as Error Status, Network Information and

System Status.
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6) Debugging andSelf-diagnosis (in New MASTER-KSeries)

Trigger and Forced I/O Enable are available for the accurate Debugging

Creating a Program

Creating aLadder Program


This chapter describes creating a program in LadderWindow using the Tool Bar.

#After selecting the Normally Open Contact icon in the Ladder Tool Bar, Move the cursor to the

place to insert the

Contact

#Click the left button of the mouse or press Enter key, then the contact input dialog box appears.
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#Type in the contact name (M0000) you want to insert and click OK button or press Enter key.

#Select the Output Coil icon in the Ladder Tool Bar and move the cursor to the next column of

P000.

Click the mouse button or press Enter key.

#Type in the Output Coil (P040) and click OK button or press Enter key.
9

Create a Project
About a Project

#A Project is the highest level to communicate with PLC and KGL for Windows.

A Project consists of Program, Parameter and Variable/Comment of Device.

#KGL for Windows deals with User Defined Programs and includes all elements necessary for

describing a Project.

#A Project consists of 3 Items (Program, Parameter and Variable/Comment) and Monitoring is

activated when the MonitoringWindow is opened. Each Item can be saved respectively for

another Project.

#Saved Items (Program, Parameter and Variable/Comment) can be used for creating other

Projects or to reuse for other Projects.

#A Project includes not only Program, Parameter and Variable/Comment, but also PLC type,

used status ofKGL and various information registered for monitoring. Thus, when you reopen

the Project after saving a Project, theWindow keeps the previous working condition.

#Only Program and Parameters can be downloaded to PLC.

#A Project is saved as *.PRJ File.

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Create a Project

#To create a New Project file, Select File--New Project« ( ) from the Project pull-down Menu.

The New Project dialog box will appear as below.

#Open a Blank Project

#It creates a new Project.

#Create from Old Files
#To create a New Project using the already existed Item (Program or Parameters or

Variable/Comment),

Select Item or items to be used by clicking the Find button in the dialog box.

#Click OK button after registering Items.

#Up to 3 items can be selected and non-selected items are set to default (Initial data).

#After selecting PLC Type and Programming Language, press the OK button. Then Project,

Message and ProgramWindows will be opened.

#Create from DOSKGL file

#To create a New Project using Items (Program, Parameter and Variable/Comment) created in

KGL for DOS,

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Select PLC Type and Programming Language after selecting already created Items inKGL for
DOS. Then, a New
Project will be opened.

#Create from KGL file

#To create a New Project from KGL file, Select already created files (*.PGM, *.CMT) from

GSIKGL in the dialog box and select PLC Type and Programming Language.

Hot-Keys for Ladder Program Mode

Simulation part

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END OFSOFTWARE DESIGN &SIMULATION

****** ******
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HARDWARE DESIGN

CHIPSPECIFICATIONS:

1).LM35 (Precision Centigrade TemperatureSensors)

Description:

The LM35 series are precision

integrated-circuit

temperature sensors, whose output voltage is linearly proportional to the Celsius

(Centigrade) temperature. The LM35 thus has an

advantage

over

linear temperature sensors calibrated in °Kelvin, as the user is not required to subtract a large constant
voltage from its output

to obtain convenient Centigrade scaling.

Features:

y Calibrated directly in ° Celsius (Centigrade)

y Linear + 10.0 mV/°C scale factor
y 0.5°C accuracy guarantee able (at +25°C)
y Rated for full í55° to +150°C range
y Suitable for remote applications
y Low cost due to wafer-level trimming
yOperates from 4 to 30 volts
y Less than 60 A current drain
y Low self-heating, 0.08°C in still air
yNonlinearity only ±1»4°C typical
y Low impedance output, 0.1

for 1 mA load

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Absolute Maximum Ratings:

Supply Voltage

+35V to í0.2V
Output Voltage
+6V to í1.0V
Output Current

10 mA

Storage Temp. TO-220 Package

í65°C
to +150°C
Lead Temp. TO-92 and TO-220 Package,

260°C.

(Soldering, 10 seconds)

2).LM317 (3-Terminal Positive Adjustable Regulator)

Description:

This monolithic integrated circuit is an adjustable 3-terminal positive voltage regulator designed to
supply more than 1.5A of load current with an output voltage adjustable over a 1.2V to 37V. It employs
internal current limiting, thermal shut-down and safe area compensation.

Features:

yOutput Current In Excess of 1.5A

y Output Adjustable Between 1.2V and 37V
yInternal Thermal Overload Protection
y Internal Short Circuit Current Limiting
y Output Transistor Safe Operating Area Compensation

Absolute Maximum Ratings:

Input-Output Voltage Differential

- 40 V.
Operating Junction Temperature - 0 ~ +125 °C
Range
Storage Temperature Range

-65 ~ +125 °C.

Temperature Coefficient of

±0.02 % /°C
19

Output Voltage

3).LM78XX (7805 & 7812)

Series Voltage Regulators

Description:

The LM78XX series of three terminal regulators is available with several fixed output voltages making
them useful in a wide range of applications. Each type employs internal current limiting, thermal shut
down and safe operating area protection, making it essentially indestructible. If adequate heat sinking is
provided, they can deliver over 1A output current. Although designed primarily as fixed voltage
regulators, these devices can be used with external components to obtain adjustable voltages and
currents.

Features

yOutput current in excess of 1A

yInternal thermal overload protection
y No external components required
y Output transistor safe area protection
y Internal short circuit current limit
yAvailable in the aluminum TO-3

package

Voltage Range:
y LM7805C 5V
y LM7812C 12V
y LM7815C 15V

20

Absolute Maximum Ratings:

Input Voltage (for VO = 5V to 18V)

35V.

(For VO = 24V)

40V.

Thermal Resistance Junction-Cases (TO-220)

5C/W.

Thermal Resistance Junction-Air (TO-220)

65C/W.

Operating Temperature Range (KA78XX/A/R)

0 ~ +125C.

Storage Temperature Range -

-65 ~ +150C.

4).HCF4093B:
QUAD 2 INPUT NANDSCHMITT TRIGGER
Description:

The HCF4093B is a monolithic integrated circuit fabricated in Metal Oxide

Semiconductor technology available in DIP and SOP packages. The HCF4093B type consists of
four Schmitt trigger circuits. Each circuit functions as a two input NAND gate with Schmitt
trigger action on both inputs. The gate switches at different points for positive and negative
going signals. The difference between the positive voltage (VP) and the negative voltage (VN) is
defined as hysteresis voltage (VH).

Features:

ySCHMITT TRIGGER ACTION ON EACH INPUTWITH NO EXTERNAL

COMPONENTS

HYSTERESIS VOLTAGE TYPICALLY 0.9V at VDD = 5V AND 2.3V at VDD

= 10V
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yNOISE

IMMUNITY
GREATER

THAN

50%OF VDD (Typ.)

y NO LIMIT ON INPUT

RISE AND FALL TIMES

y QUIESCENT CURRENT

SPECIFIED UP TO 20V

y S T AND ARDI ZE D

SYMMETRICAL
OUTPUT
CHARACTERISTICS

y 5V, 10V AND 15V

PARAMETRIC

RATINGS

y INPUT LEAKAGE CURRENT II = 100nA (MAX) AT VDD = 18V TA = 25°C

y 100% TESTED FORQUIESCENT CURRENT.

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ABSOLUTE MAXIMUM RATINGS:

23

Supply Voltage

-0.5 to +22 V

DC Input Voltage

-0.5 to VDD + 0.5 V

DC Input Current

± 10 mA

Power Dissipation per Package

200 mW

Power Dissipation per Output Transistor

100 mW

Operating Temperature

-55 to +125 °C

Storage Temperature

-65 to +150 °C

Power supply:
This comprises of 12V DC & 5V DC supply for the four sensors (2 level sensors, 1 temperature

sensor & 1pressure sensor) used in the boiler. The 230V AC supply is first stepped down to

12V AC using a step down transformer. The output of this transformer is then passed through a bridge
rectifier to convert it to 12V DC output and hence to 5V. For the voltage consistency, IC 7812 & IC 7805
chips are used. The 12V DC and 5V hence obtained is utilized to activate all the four sensors.

DESIGN OF LIQUID LEVELSENSOR

24

Most of the sensor placed inside the water cause electrolytic reaction between liquid and sensor causing
loss of effectiveness. One solution to this problem is to ensure an AC potential rather than DC potential
between the electrodes. The constant reversal of electrode polarity drastically inhibits the electrolytic
process so that corrosion is considerable reduced and effectiveness doesn¶t hampered.

In this liquid level sensor AC is generated by an oscillator by connecting a capacitor (C1) to the input of
IC4093 (a NAND) gate and proving a feedback through the resistor (R1). This AC current is given to the
capacitor (C4) to charge up through the AC coupled capacitors C2 and C3. Between C2 and C3 two
sensor electrodes are placed so that when the liquid touches the electrode, a conducting path is being
created by the liquid so that C4 can be charged. Two diodes D1 and D2 provide blockage to discharge
capacitor C4. This high input of the charged capacitor C4 is given to the IC4093 whose output is used to
drive the base of transistor BC557. A relay is connected to ground through BC557. As the transistor is
driven by IC4093 which drive relay in and the 230 volt ac output of relay is used to drive the motor.

Circuit diagram of liquid level sensor

Design of temperature sensor

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VOLTAGE REGULATOR CIRCUIT

A voltage regulator circuit provides a fixed value of voltage for particular values of circuit components. A
12 volt DC voltage circuit can be designed by connecting a 230:12 volt transformer, a bridge rectifier
circuit and a capacitor, an IC7812.The transform gives 12 volt AC output which is rectified by bridge
circuit, a capacitor is used to bypass the AC component and the IC7812 is used to provide constant 12
volt output which is use to drive other instruments.

Circuit diagram for voltage regulator circuit

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Future work:

The 2nd stage of the project is to be done in the successive semester.

2nd stage of the project involves:

1. Designing the pressure sensor circuit
2. Interfacing of sensors with the plc trainer kit.
3. Implementing the software program.
4. Construction of boiler setup & incorporation of the sensor within the boiler.

REFERENCE

1.LM 35 Precision Centigrade Temperature Sensors, National semiconductors, November

±2000.

2. LM78XX Series Voltage Regulators, National semiconductors, May ± 2000.

3. UserManual for PLC Trainer Kit,LG Programmable logic controller KGL for windows

[MASTER-K Series].

4.www. f airchildsemi. com

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PROJECT GUIDE:

PROJECT GROUP MEMBERS:

Mr. JAYANTKUMARKAR

JAYANTAKUMAR MUDULI (0601212514)

MS. LIMALI SAHOO

CHETAN DAS

(0601212524)

SOURAV PRASADKANUNGO (0601212527)

SARITKUMAR SI

(0601212533)