PLC based boiler pressure monitoring and controlling System

Aim:This project is used to maintain the boiler pressure to avoid the harmful condition in industrial area. Description:Boilers use a heat source, usually combustion of a fossil fuel, to heat water to produce hot water or steam. Boilers fired with coal, wood and other solid fuels powered major industries in the 19th century. Boilers today burn natural gas and oil as well as solid fuels and continue to play a major role in manufacturing, heating and electricity generation. Boilers are essential in many energy-intensive industries and comprise a significant component of U.S. energy consumption. Boilers can be characterized by the configuration of the heat transfer surfaces either fire tube or water tube - and by the fuel-burning system. The appropriate configuration is determined by the desired fuel, steam conditions and capacity. Problems:There are several problems within a boiler system some of which require chemical treatment or other mechanical means to overcome them. The major problems are:
o o o o o

Scale Corrosion Boiler Water Carryover Sludge Deposition High steam Pressure

These can cause problems in all parts of the system starting with the feed tank leading through the boiler and into the condensate system. The problems arise from the quality of the water used within the steam raising system and the manner in which the system is operated and hence it is not only chemical issues that need to be addressed. In extreme cases is has been known for steam boilers to explode causing much damage and even death. So it is for this reason that strict standards have arisen on

how to treat and maintain boilers and associated systems. Then there are efficiency problem with excess fuel being used to raise the steam or leaks causing loss of water, chemicals and energy from the system. All of these issues are avoidable with simple chemicals and good maintenance regimes. Here we are just considering on problem of high pressure. Project Theme:To maintain the pressure of boiler steam pressure relive valve is using, by using this project we can set the pressure levels i.e low and high pressure. If steam pressure level is going down then inlet valve will open water is getting in boiler or if steam pressure goes high then steam pressure relive valve will open all this process will try to run through plc. Block Diagram:-

Input signals are from boiler.

Process On off switch Signal conditioning ckt PLC Pressure relive valve

Pressure sensor

Power Supply

Components Required: Pressure sensor ON-OFF switch Pressure relive valve Power supply PLC

Advantages of PLC:

Flexibility: One single Programmable Logic Controller can easily run many machines. Correcting Errors: In old days, with wired relay-type panels, any program alterations required time for rewiring of panels and devices. With PLC control any change in circuit design or sequence is as simple as retyping the logic. Correcting errors in PLC is extremely short and cost effective. Space Efficient: Today's Programmable Logic Control memory is getting bigger and bigger this means that we can generate more and more contacts, coils, timers, sequencers, counters and so on. We can have thousands of contact timers and counters in a single PLC. Imagine what it would be like to have so many things in one panel. Low Cost: Prices of Programmable Logic Controlers vary from few hundreds to few thousands. This is nothing compared to the prices of the contact and coils and timers that you would pay to match the same things. Add to that the installation cost, the shipping cost and so on. Testing: A Programmable Logic Control program can be tested and evaluated in a lab. The program can be tested, validated and corrected saving very valuable time. Visual observation: When running a PLC program a visual operation can be seen on the screen. Hence troubleshooting a circuit is really quick, easy and simple.