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HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS MAJOR: AUTOMATION AND CONTROL ENGINEERING TECHNOLOGY INDUSTRIAL NETWORK COMMUNICATION APPLICATION INTO CONTROLLING AND MONITORING BOILER SYSTEM IN THERMAL POWER PLANT ADVISOR: NGO VAN THUYEN STUDENT'S NAME: PHAN VAN LAM STUDENT’S ID: 15151045 STUDENT'S NAME: HUYNH NHAT THANG STUDENT’S ID: 15151077 SKL 0 0 HO CHI MINH CITY, JANUARY 2020 an HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT INDUSTRIAL NETWORK COMMUNICATION APPLICATION INTO CONTROLLING AND MONITORING BOILER SYSTEM IN THERMAL POWER PLANT Advisor: ASSOC.PROF NGO VAN THUYEN PHAN VAN LAM Student’s ID: 15151045 HUYNH NHAT THANG Student’s ID: 15151077 Major: Automation And Control Engineering Technology Ho Chi Minh City, January 2020 an an an THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, January …, 2020 ASSIGNMENT Student’s full name 1: Phan Van Lam Student’s ID: 15151045 Student’s full name 2: Huynh Nhat Thang Student’s ID: 15151077 Major: Automation and Control Engineering Technology Type of training: Full time Academic year: 2015 Class: 15151CL2 I TITLE OF THE GRADUATION PROJECT INDUSTRIAL NETWORK COMMUNICATION APPLICATION INTO CONTROL AND MONITOR BOILER SYSTEM IN THERMAL POWER PLANT Advisor: Assoc Prof Ngo Van Thuyen II MISSON Initial materials: - Hardware devices at Rockwell Automation Laboratory - Process of operating and monitoring boilers in thermal power plants - Communication applications in practice Content of the project: - Studying communication network solutions in boiler operation and monitoring - Program design for each PLC station - Design of SCADA interface to operate and monitor the system - Writing thesis and report III DATE OF ASSIGNMENT: 16/9/2019 IV DATE OF SUBMISSION: 25/12/2019 V ADVISOR: Assoc Prof Ngo Van Thuyen ADVISOR CONTROL ENGINEERING AND AUTOMATION an THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, January …, 2020 IMPLEMENTATION SCHEDULE Student’s full name 1: Phan Van Lam Student’s ID: 15151045 Student’s full name 2: Huynh Nhat Thang Student’s ID: 15151077 Major: Automation and Control Engineering Technology Type of training: Full time Academic year: 2015 Class: 15151CL2 Tittle : INDUSTRIAL NETWORK COMMUNICATION APPLICATION INTO CONTROL AND MONITOR BOILER SYSTEM IN THERMAL POWER PLANT Advisor: Assoc Prof Ngo Van Thuyen DATE CONTENT IMPLEMENTATION 16/9/2019 Receiving graduate topic 1/10/2019 Study network communication applications in industry 15/10/2019 Survey and research on equipment's priciple operation at the Rockwell Automation laboratory 15/11/2019 Hardware design 30/11/2019 Software design 15/12/2019 Perfecting and optimizing the system 25/12/2019 Write and finalize report ADVISOR’S CONFIRM Ho Chi Minh City,………………… Advisor an THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, January …, 2020 ADVISOR’S EVALUATION SHEET Student name: Phan Van Lam Student ID: 15151045 Student name: Huynh Nhat Thang Student ID: 15151077 Major: Automation and Control Engineering Technology Project title: INDUSTRIAL NETWORK COMMUNICATION APPLICATION INTO CONTROL AND MONITOR BOILER SYSTEM IN THERMAL POWER PLANT Advisor: Assoc Prof Ngo Van Thuyen EVALUATION Content of the project: Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Overall evaluation: (Excellent, Good, Fair, Poor) Mark:………………(in words: .) Ho Chi Minh City,……………………… ADVISOR (Sign with full name) an THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -Ho Chi Minh City, January 20, 2020 Student name: Student ID: Student name: Student ID: Major: Project title: Name of Reviewer: EVALUATION Content and workload of the project Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Overall evaluation: (Excellent, Good, Fair, Poor) Mark:……………….(in words ) Ho Chi Minh City,………………………… REVIEWER (Sign with full name) an THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness Student name: Student ID: Student name: Student ID: Major: Project title: Name of Defense Committee Member: EVALUATION Content and workload of the project Strengths: Weaknesses: Overall evaluation: (Excellent, Good, Fair, Poor) Mark:……………….(in words: ) Ho Chi Minh City, month day, year COMMITTEE MEMBER (Sign with full name) an an (7): Emergency exhaust steam valve signal light (8): Emergency valve discharge lights in case the steamdrum is over water (9): Blowdown valve signal light Figure 5.2 Hardware used in system 66 an 5.2 Contruction Result • Authorization Access Before operating the system, users must log in Display login is shown in figure 5.1, assign different access rights and not allow unauthorized people to access the system If the user logs in, enter the wrong name or the wrong password, there will be an error message, refusing to log in as shown in Figure 5.2, after login successfully, you can see a current parameter or you can set parameter if you have enough permission as shown figure 5.3 Figure 5.3 Login display 67 an Figure 5.4 Insufficient access right Figure 5.5 After success login On the level operation page as shown in figure 5.4, we can monitor and operate the entire system The graph on this page displays the parameters of feed level, steam drum, furnace temperature within 24 hours so that the operator can capture the current 68 an status of the system, and predict trends To be able to plan appropriate operations The page is divided into areas to monitor or access level pages: water supply system, steam supply system, combustion system Figure 5.6 Level operation system display The level screen page provides a user interface to monitor and operate sub-unit components Detailed visual interface, easy to operate As shown in Figure 5.7, the system controls the water level steamdrum for the system, the left shows the status 69 an of the four water pump motors, and can adjust the valve flow into the steam drum The right shows the water level graph, the operator observes the trend to be able to adjust the water level accordingly by controlling water feed pump capacity Figure 5.7 Level water level supply system display Figure 5.8, Steam supply operation display In this display, the operator will adjust the output steam pressure to operate the tuabine At the same time, the system performance can be adjusted by adjusting the flow valve Gauge charts will respond to steam pressure and steam valve out You can see the details of the steam tube to supply for a turbine in the middle of the screen 70 an Figure 5.8 Level steam supply system display Figure 5.9, combustion system display,in this display, the left display can control the conveyor and forced fan to supply material for combustion Adjust the furnace pressure by adjusting the introduced fan, so that the combustion is completely needed to adjust the primary fan motor to provide air for the combustion process The operator can control furnace pressure and temperature furnace automatically by setting on this page, the right page can see the oven temperature furnace trend 71 an Figure 5.9 Level combustion system display On page level 3, will provide users with a detailed interface of the components in the system, we have pages level As shown in Figure 5.10, the details page of the water supply system, the operator can see details of the component of the system, the components to heat the water before returning to the steam drum, and the temperature of the water through each heating process The operator can see the performance of heating elements and predict the performance so that corrective actions can be used similar to the above, Figure 5.11 details the components of the combustion system 72 an Figure 5.10 Detail of water supply system Figure 5.11 Detail of combustion system 73 an In Figure 5.12 is a detailed trend of level steam dum On this display, you can view the entire situation of the level steam trends at any time.Operators can see setpoints and water levels To stabilize the water level in a steam drum,we used a PID controller, you can look on the graph, the PID controller can meet the water level stability well Figure 5.12 Level steam drum trend In Figure 5.13 is a detailed trend of the steam out On this display, you can view the entire situation of the pressure and temperature steam at any time Figure 5.13 Steam out trend an 74 In Figure 5.12 is a detailed trend of temperature furnace On this display, you can view the entire situation of the temperature furnace trends at any time.Operators can see setpoints and temperature To stabilize the temperature in a furnace,we used a PID controller, you can look on the graph, the PID controller can meet the water level stability well PID controller has not stable temperature correctly, because of the large inertia of the temperature We Can be overcome by adjusting the coefficient Kp, Ki, Kd Figure 5.14 Temperature trend display 75 an In Figure 5.15, the operator can see the warnings and be saved on this page to remind the operator to troubleshoot Figure 5.15 Alarm display 76 an CHAPTER 6: CONCLUSION AND DEVELOPMENT DIRECTION 6.1 Conclusion 6.1.1 Advantages of System Based on the research process, the system has operated and achieved the following technical requirements: • Application of communication network such as Ethernet, DeviceNet… to interchange data, motor control • Using PID to stabilize boiler temperature, level water… • Connecting sensors, actuators to I/O Modules • Having a friendly Scada 6.1.2 Not achieved elements Besides the achieved successes, system still has a number of below disadvantages: • The limited of line network in Produced and Consumed protocol • Modelling at the simulation level • Not apply ControlNet into system 6.2 Directions For Future Research According to the success of system at simulation level, we suggest a lot of following ideas to develop system become a professionally industrial system: • Use additional SQL to retrieve data as needed • Apply other communication networks such as ControlNet, Modbus, • IoT applications in industrial systems 77 an REFERENCE Vietnamese [1] PGS.TS Ngô Văn Thuyên PGS TS Trương Đình Nhơn (2017), “Lập trình PLC Allen-Bradley”, Nhà xuất ĐHQG Tp HCM,114 trang [2] Th.s Tạ Văn Phương (2015), Bài giảng Rockwell Automation English [3] Rockwell Automation Process Solutions User Group (November, 2011) “The High Performance HMI” [4] KARL J ÅSTRÖM, PH.D., The Instrumentation, Systems, and Automation Society; Sub edition (January 1, 1995), 343 pages 78 an an S an K L 0
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