Industrial network communication application into controlling and monmitoring boller system in thermal power plant

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS MAJOR: AUTOMATION AND CONTROL ENGINEERING TECHNOLOGY INDUSTRIAL NETWORK COMMU

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

HO CHI MINH CITY, JANUARY 2020

SKL 0 0 6 9 0 0

GRADUATION PROJECT

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION

FACULTY FOR HIGH QUALITY TRAINING

INDUSTRIAL NETWORK COMMUNICATION APPLICATION INTO CONTROLLING AND

MONITORING BOILER SYSTEM IN

THERMAL POWER PLANT

Advisor: ASSOC.

Student’s ID: 15151045

PROF NGO VAN THUYEN PHAN VAN LAM

HUYNH NHAT THANG Student’s ID: 15151077

Major: Automation And Control Engineering Technology

Ho Chi Minh City, January 2020

THE SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom– Happiness

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

1 Initial materials:

- Hardware devices at Rockwell Automation Laboratory

- Process of operating and monitoring boilers in thermal power plants

- Communication applications in practice

2 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

IV DATE OF SUBMISSION: 25/12/2019

V ADVISOR: Assoc Prof Ngo Van Thuyen

ADVISOR CONTROL ENGINEERING AND AUTOMATION

THE SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom– Happiness

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

CONFIRM

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

Ho Chi Minh City,………

Advisor

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

2 Strengths:

3 Weaknesses:

4 Approval for oral defense? (Approved or denied)

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 1 Content and workload of the project

2 Strengths:

3 Weaknesses:

4 Approval for oral defense? (Approved or denied)

5 Overall evaluation: (Excellent, Good, Fair, Poor)

6 Mark:……….(in words )

Ho Chi Minh City,………

REVIEWER

(Sign with full name)

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 1 Content and workload of the project

2 Strengths:

3 Weaknesses:

4 Overall evaluation: (Excellent, Good, Fair, Poor)

5 Mark:……….(in words: )

Ho Chi Minh City, month day, year

COMMITTEE MEMBER

(Sign with full name)

i

ACKNOWLEDGEMENT

So we can complete this thesis, first of all , we would like to thank to all lecturers and friends at Ho Chi Minh University of technology and education who taugh, attached, and helped us to be more mature in academic pathways

Further, we would like to express to my deepest gratitude to instructor Asociate Professor Ngo Van Thuyen, who guided and provided useful experiences in life as well as practical help.We were able to successfully complete this project

Finally, sincerely thank you to our family for their endless love and always supporting

us during the time we studied at Ho Chi Minh University of Technology and Education

Although we tried to complete the essay very well, but the project cann’t be avoid mistake We are looking forward to receiving the feedback of the council and tutor for better topic

Sincerely thanks!

ABSTRACT

Nowadays, in the process of building our country to become a growing industry country, making life more comfortable and modern, this requires higher automation applications in everyday life and production

On the other hand, with the rapid development of the industrialization process, almost factories apply modern technologies into their systems to help optimize monitoring and operation Therefore, automation technology is becoming a multi-tasking technology, it fulfills the requirements of industry such as manufacturing, building,

… and especially in the electrical energy industry With an important role of automation applications in industrial development Most factories apply scientific advancements in their production lines to increase the productivity and quality of the system, decrease the cost of damage drain Besides, to ensure high accuracy in production, factories are forced to apply automation solutions in their lines

To do that, a piece of modern equipment and a system is required to meet these requirements With the rapid development of information technology, electronic technology has appeared a type of device, this device has met the above requirements,

it is a programmable controller "PLC" Therefore, by implementing the use of PLC

in their automation process, industries will take a step forward in the era of new industrialization PLC plays a very important role in the world of automation This is the main part of the system, including the whole process simple, flexibly and accurately There are many types of PLCs from many different brands such as Siemens, Omron, Rexroth, Mitsubishi, with many different functions and features And the PLC we choose to use in this topic is PLC of Rockwell

In this project, we used various technologies such as sensors, PLCs and applications

of a communication network to essentially simulate a system that can monitor and collect data in thermal power plants The boiler is one of the most important equipment in any power plant which requires continuous monitoring and inspection

at frequent intervals There are possibilities of errors at measuring and various stages involved with human workers So, a reliable monitoring system is necessary to avoid catastrophic failure, which is achieved by a Programmable Logic Controller & Supervisory Control and Data Acquisition system This thesis outlines the design and development of a boiler automation system using PLC, SCADA, and sensors PLC and SCADA interfaced via communication cables The initial phase of the thesis focuses on passing the inputs to the boiler at a required temperature, so as to constantly maintain a particular temperature in the boiler SCADA is used to monitor the boiler temperature, pressure and water level using different sensors and the corresponding output is given to the PLC which controls the boiler temperature, pressure, and water level If the temperature and pressure inside the boiler exceed the predefined value then the entire system is shut down In case of emergency different

iii

automated check valves are used to release pressure, steam and inform the concerned authority through the alarm The boiler automation ladder diagram is designed using Rslogix 5000 software and SCADA design is done by factorytalk view

CONTENTS

ACKNOWLEDGEMENT i

ABSTRACT ii

CONTENTS iv

LIST OF ABBREVIATES vi

LIST OF FIGURES vii

LIST OF TABLES ix

CHAPTER 1: INTRODUCTION 1

1.1 Reason for choosing topic 1

1.2 Objective 2

1.3 The Thesis’ Content 3

1.4. Method Research 3

1.5 Thesis’s Scope 3

CHAPTER 2: THEORETICAL BASIC 5

2.1 Overview system 5

2.1.1 Furnace 6

2.1.2 Water Supply and Steam Drum 7

2.1.3 Supper Heater 7

2.1.4 Reheater 8

2.1.5 Economizer 8

2.1.6 External Supply System 8

2.1.7 Combustion System 9

2.1.8 Air Heater 9

2.1.9 Coal Mill System 9

2.1.10 Boiler Discharge System 10

2.1.11 Dust Blowing System 10

2.2 Industrial Network 10

2.2.1 Introduction 10

2.2.2 Advantages of Using Industrial Network 11

2.2.3 Hierarchical Levels in Industrial Communication Networks 11

2.2.4 Industrial Communication Networks of ALLEN BRADLEY 13

2.3 Transfer Data Based On Produced Tag And Consumed Tag Protocol 17

2.4 Allen Bradley PLC Series 18

2.5 Overview About SCADA System 19

2.5.1 SCADA System Components 19

2.5.2 The Functions of SCADA Systems: 21

2.5.3 Hardware and Software of SCADA System: 21

2.6 Allen Bradley PowerFlex drives series 23

2.7 Motors 25

2.8 Sensors 25

2.9 PID Controller And Function 27

CHAPTER 3: HARDWARE DESIGN 29

3.1 Hardware Requirements 29

3.2 Hardware diagram 29

v

3.3 Devices Selections 30

3.3.1 Compactlogix 1769-L32E 30

3.3.2 Controllogix 1756-L61 31

3.3.3 Analog Input 1769-IF4 Module 34

3.3.4 Analog Output 1769OF2 Module 34

3.3.5 Stratix 2000 35

3.3.4 HMI Panelview Plus 7 36

3.3.5 Powerflex 525 Inverter 37

3.3.6 Powerflex 700S AC DRIVE 38

3.3.7 Danfoss And Micro 420 Inverter 38

3.3.8 PH Sensor 40

3.3.9 Level Water Sensor: 41

3.3.10 Temperature Sensor 42

3.3.11 Pressure Sensor 43

3.3.12 Industrial Fan and Motor 44

3.3.13 Steam Turbine and Steam Valve 46

3.4 Powered Circuit And Control Circuit 47

CHAPTER 4: SOFTWARE DESIGN 50

4.1 Plc Program Design 50

4.2 Interchange Data Between PLC Stations 52

4.2.1 The Importance of Interchange Data 52

4.2.2 Data Transmission Process 52

4.3 SCADA System Design 54

4.3.1 Design Requirement 54

4.3.2 HMI Design 54

4.3.3 Authorization 62

4.3.4 Alarm 63

CHAPTER 5: RESULT 65

5.1 Result Of Hardware 65

5.2 Contruction Result 67

CHAPTER 6: CONCLUSION AND DEVELOPMENT DIRECTION 77

6.1 Conclusion 77

6.1.1 Advantages of System 77

6.1.2 Not achieved elements 77

6.2 Directions For Future Research 77

REFERENCE 78

LIST OF ABBREVIATES

PLC: Programmable Logic Controller

FC: Frequency Converter

HMI: Human Machine Interface

SCADA: Supervisory Control and Data Acquisition

AO: Analog Output

DI: Digital Input

DO: Digital Output

EMS: Emergency Stop

IoT: internet of thing

PID: Proportional Integral Derivative

RTU: Remote Terminal Unit

DCS: Distributed Control Systems

RTD: Resistance Temperature Detectors

vii

LIST OF FIGURES

Figure 1.1 Depveloping coal-fired power in Viet Nam 2

Figure 2.1 Diagram of thermal power plants 5

Figure 2.2 Structure of Vung An’ s thermal power 6

Figure 2.3 Coal mill 10

Figure 2.4 Hierarchy of an industrial automation system 11

Figure 2.5 Structure of Allen Bradley network 14

Figure 2.6 Ethernet/IP network connection structure 14

Figure 2.7 Devicenet connection structure 15

Figure 2.8 ControlNet connection structure 16

Figure 2.9 Modbus connection structure 17

Figure 2.10 Transfer data between multiple controller 17

Figure 2.11 Factory talkview application 22

Figure 3.1 Hardware diagram 29

Figure 3.2 Compactlogix 1769-L32E 30

Figure 3.3 Controllogix 1756-L61 32

Figure 3.4 Stratix 2000 35

Figure 3.5 HMI panelview plus 7 36

Figure 3.6 PowerFlex 525 Inverter 37

Figure 3.7 Danfoss (Left) And Micro 420 Inverter (Right) 39

Figure 3.8 CPS 11D AND CPS41D sensor 40

Figure 3.9 CLM36-10 level water sensor 41

Figure 3.10 CLM36-10 connection diagram 41

Figure 3.11 ST133 transmitter 42

Figure 3.12 ST133 connection diagram 43

Figure 3.13 welding gauge ISO 5171 44

Figure 3.14 SIEMENS 1LA7096-4AA10 motor 45

Figure 3.15 Steam turbine and steam valve 46

Figure 3.16 Powered circuit 47

Figure 3.17 Sensor wiring diagram of the combustion station 48

Figure 3.18 Sensor wiring diagram of the boiler station temperature 48

Figure 3.19 Sensor wiring diagram of the material supply 49

Figure 4.1 State diagram system 50

Figure 4.2 Self-operation diagram of system 51

Figure 4.3 Data transmission diagram 52

Figure 4.4 Hierarchy for display 55

Figure 4.5 Login Display 56

Figure 4.6 Level 1 process area overview display 57

Figure 4.7 Process unit of water system display 58

Figure 4.8 Process unit of combustion system display 59

Figure 4.9 Process unit of steam supply display 60

Figure 4.10 Process detail of combustion system 61

Figure 4.11 Process detail of water system 61

Figure 4.12 Authorization groups 62

Figure 4.13 Alarm of system 63

Figure 5.1 Simulate sensors used in the system 65

Figure 5.2 Hardware used in system 66

Figure 5.3 Login display 67

Figure 5.4 Insufficient access right 68

Figure 5.5 After success login 68

Figure 5.6 Level 1 operation system display 69

Figure 5.7 Level 2 water level supply system display 70

Figure 5.8 Level 2 steam supply system display 71

Figure 5.9 Level 2 combustion system display 72

Figure 5.10 Detail of water supply system 73

Figure 5.11 Detail of combustion system 73

Figure 5.12 Level steam drum trend 74

Figure 5.13 Steam out trend 74

Figure 5.14 Temperature trend display 75

Figure 5.15 Alarm display 75

ix

LIST OF TABLES

Table 2-1 Type of Devicenet cable 16

Table 2-2 Exchange data between PLCs 18

Table 3-1 Compactlogix 1769-PA2 technical data 31

Table 3-2 CPU CompactLogix 1769-L32E technical data 31

Table 3-3 1756-PA75/B power supply technical data 32

Table 3-4 CPU ControlLogix 1756-L61 technical data 33

Table 3-5 EtherNet/IP1756-EN2T technical data 33

Table 3-6 DeviceNet 1756-DNB technical data 34

Table 3-7 Analog Input 1769-IF4 Module technical specification 34

Table 3-8 Analog Output 1769-OF2 Module 35

Table 3-9 Stratix 2000 technical data 36

Table 3-10 HMI panelview plus 7 technical data 36

Table 3-11 PowerFlex 525 data specifications 37

Table 3-12 Powerflex 700s technical data 38

Table 3-13 Micro master 420 technical data 39

Table 3-14 Danfoss Inverter technical data 39

Table 3-15 CLM36 technical data 41

Table 3-16 RTDS technical data 42

Table 3-17 ST133 technical data 43

Table 3-18 Welding gauge ISO 5171 technical data 44

Table 3-19 SIEMENS 1LA7096-4AA10 motor technical data 45

Table 3-20 Steam turbine SST-3000 technical data 46

Table 3-21 Type 3281-1 pneumatic steam conditioning valve technical data 47

Table 4-1 Transferred-data from central station (cpu32) 53

Table 4-2 Transferred-data from the other stations to central station (cpu32) 53

Table 4-3 Authorization function for user 63

CHAPTER 1: INTRODUCTION 1.1 Reason for choosing topic

At the International Conference on Renewable Energy Development to Reduce Carbon in Vietnam, Deputy Minister of Industry and Trade Cao Quoc Hung said that

in the past 20 years, Vietnam has achieved a GDP growth of 6-7% However, on the engraving side, electricity demand has increased by 13% for the period 2000-2010 and over 11% for the period of 2011-2016 (in 2018 it was over 10%)

Looking to the future, the forecasts indicate that from now until 2030, Vietnam's economy will continue to grow at a high rate of 6.5-7.5% per year, and so the high priority needs must be reserved To ensure energy needs for the country's sustainable development

According to the National Power Development Plan approved by the government, the installed capacity of the whole country will reach 130,000MW in 2030 compared

to the current 47 MW As such, approximately 83,000 MW of new power source will need to be built and put into operation by 2030, along with the construction and installation of transmission and operation systems

Meanwhile, hydroelectricity currently meets 40% of the demand, but the exploitation potential is almost exhausted, it is unlikely to be further developed Other alternative power sources are also facing many difficulties because Vietnam has temporarily stopped implementing nuclear power projects, renewable energy sources have not been implemented due to high cost, and the transmission system has not been met The demand for loans to develop power sources is also facing many difficulties According to the Ministry of Industry and Trade, the coal-fired thermal power industry in Vietnam accounts for 39% of the total and is likely to increase and become more important in the energy industry ( Figure 1.1 )

Although, the current world trend is increasingly restricting the use of coal-fired power for reasons that have not overcome the harmful effects of C02 on the environment, and according to many experts in Vietnam, in the context If renewable energy, with high costs, exhausted gas, developing coal energy is the solution to ensure energy security of the country The boiler is one of the solutions to ensure the environment

Currently, coal power can take advantage of bad coal to create clean electricity, production products can make unburnt bricks and additives for cement production, opening a new direction for the thermal power industry , making effective use of Vietnam's resources, reducing coal import pressure

post-2

Figure 1.1 Depveloping coal-fired power in Viet Nam

Therefore, the boiler is one of the most important equipment in any power plant and

it requires constant monitoring and regular inspection Errors can occur due to various factors such as the environment and people, etc Therefore, a reliable control and monitoring system are needed to optimize system operation and minimize it The process of learning and grasping the system, our team decided to implement the topic

"Designing control and monitoring system of boilers in thermal power plants"

1.2 Objective

The paper focuses on processing the input sensor signals of the boiler to maintain the boiler temperature continuously at the required temperature of the system SCADA will be used to monitor the temperature and water level of the boiler with different sensors analog to supply PLC to control parameters such as temperature, water level and pressure in the boiler …

The system will be controlled and monitored by an HMI screen, HMI screen communicating with the PLC by a communication network And the interface is designed by Rockwell's specialized software, Factorytalk view In an emergency, the system will have automatic valves to help the system release pressure and steam, emergency stops the system and automatically notify the operator and related agencies

In this topic, we will focus on the applications of Rockwell communication network and directly apply to boiler systems in thermal power plants

1.3 The Thesis’ Content

The team will focus its research on:

• Components of the actual boiler system

• Operating procedures and stringent standards of the boiler

• Incidents may occur in the actual oven

• Research on using PID to stabilize boiler temperature

• Researching on inverter application in motor control

• Ways to stabilize the water level in the steamdrum

• Control the flow and pressure valves in the furnace

• Application of Ethernet communication network, Controlnet, DeviceNet to the real system

• Design a suitable SCADA system

1.4 Method Research

Research and deployment methods include:

• Under the knowledge and guidance of Assoc Prof Dr Ngo Van Thuyen

• Through the internet's scholarly materials

• Through practical experience of the previous person

• The system will be designed and implemented with modern equipment of rockwell automation at the laboratory of Ho Chi Minh University of Technology

1.5 Thesis’s Scope

The implementation of the project is related to the limitation of the project.In real life, the thermal power plant with large investment, expensive equipment is used, with limited conditions as well as time, the system is limited to simulation; However, the system will be simulated and based on real parameters, will make use of all laboratory

4

equipment and specialized knowledge of automation to design a system suitable for the intuitive interface easy to use.Additionally, advanced technologies such as a communication network and PID control algorithm are used to make the system more optimal

Figure 2.1 Diagram of thermal power plants

CHAPTER 2: THEORETICAL BASIC 2.1 Overview system

Over the years, the demand for high quality, higher efficiency, and automated machines have increased in the industrial sector of power plants Power plants require constant monitoring and inspection at regular intervals There are many boiler equipment These boiler equipment generate high-temperature water of steam temperature This steam level temperature is used to generate electricity and steam is applied to the turbine part After the electricity is generated, steam is supplied to various plants for reuse If the supply of high temperatures drops too low temperatures, it will be used for all other plants that need low temperatures And during operation, there is the possibility of technical errors and various stages related

to human operation To automate a power plant and minimize human intervention, a PLC & SCADA system is needed to optimize operation, minimize risk, and Figure 2.1 shows the basic components in boilers used in today's thermal power plants

6

Figure 2.2 Structure of Vung An’ s thermal power

A thermal power plant uses a boiler to convert the heat from raw materials and feed

it and turn it into steam by saturated steam, and is passed through a super heater and becomes super steam Superheated steam is fed into the rotating turbine to control a generator (generator) After it passes through the turbine, the steam is condensed in a condenser and recycled to where it is heated; This is called a Rankine cycle The biggest difference in the design of thermal power plants is due to the different fuel sources

In any thermal power plant, there are main components as follows:

• Coal processing and burning system

• Smoke and wind system

• Fuel oil combustion system

• Dust blowing system

• Furnace discharge system

• Electrostatic dust removal system

2.1.1 Furnace

The main raw material is used for the boiler is coal with poor characteristics, so the construction of the burner should ensure the retention time of coal powder in the high temperature area, and increase the smoke recirculation to the foot of the burner and enhance radiant heat exchange between combustion products

In order to meet this requirement, in reality, the boiler of Vung An 1 Thermal Power Plant uses a boiler with W-shaped flame This is the type that is recommended to be used by major boiler manufacturers in the world such as Mitsui Babcock, Babcock Wilcock, Alstom Power,

The combustion chamber is made up of male units and is welded together to form a gas glass burner Each frame consists of several inner grooved tubes welded with gills

The lower part of the combustion chamber is extended to the front and back to form two arches as a place for firing coal powder Inside this part is covered with refractory materials to limit the heat absorption of the kiln wall so that the coal soon catches fire and burns more stably

Steam generators are reinforced with steel beams to withstand fluctuations in combustion chamber pressure (minimum is  70 mbar)

2.1.2 Water Supply and Steam Drum

Water supplied to the boiler must meet strict input quality requirements, and be continuously pumped by high-pressure water into the steam drum with specific pressure, so that the system operates continuously For the actual boilers, the amount

of water fed to the steam drum and the natural circulation remembers the difference

in the density of water and steam in the pipe, without any special equipment

The air drum has a welding structure with hinged doors that open inwards at each end

The steam drum in addition to receiving water, saturated steam separator also has the function of ensuring the circulation of the steam in the steam tube rigs Inside the steam drum, there are 392 cyclone-type steam separators

At the top of the steam, chamber is a set of waves to separate the droplets of water from the stem in a saturated steam stream

The water level in the steam drum is controlled within + -25mm, around the average water level by the water level control system

2.1.3 Supper Heater

After the water is converted into saturated steam, the amount of saturated steam is passed through the superheater to increase the temperature and pressure and create the superheated steam, the superheated steam will be directed directly to the steam turbine converting heat energy into electricity supplied to generators

There are sets of ceiling overheating, cage overheating, level 1 overheating, curtain overheating and final overheating

Adjust the temperature of superheated steam by reducing the 2-stage, first-grade spray on the end of the screen superheater, level 2 at the end superheater

The spray water is taken from the pump feeder, which is high-quality water so it does not cause steam pollution

8

2.1.4 Reheater

The re-heater is used to reuse the steam after passing through the battery, there is still

a large amount of heat, it will lead to the superheater to heat up and continue to use for the tuabine 2 system that needs some heat lower power

The reheater consists of two levels, between two levels have a transfer manifold to reduce pressure loss Level 1 is placed in a box-shaped half created by a cage superheater, level 2 is placed in the horizontal section of the combustion chamber output

In the inlet and outlet pipes are arranged spring-style safety valves Regulating the temperature of re-heat steam by changing the aperture of the smoke flow shield through level 1 heat recovery unit Although the equipment is complex and has large control inertia, it is a safety measure to eliminate the possibility of re-heat steam is humid due to spraying water in the case of using a spray adjustment method.However,

at the inlet of the re-heater, there is still an aerosol-type suppressor for emergency use, the spray water for this blast is supplied from the intermediate level of the water pump

2.1.5 Economizer

When the water is fed into the steam drum, the ambient temperature will cause loss

of fuel burn, so people often use the Economizer to get the heat from exhaust fumes

to conduct water heating before feeding into the steam drum, which saves a significant amount of fuel burned

The Water Heater is used a smooth tube and arranged below the level 1 preheater, the first pipes are protected by abrasion-resistant steel pipes by flyash

To protect the heater at start-up, arrange a recirculation line from the drum, to the manifold and the heater

2.1.6 External Supply System

Feed water: starting from the outlet of the high-pressure water heater to the inlet of the conomizer

Main steam line: where to start from the oulet of the superheater collector to the inlet

of the main valve of high-pressure turbine Spring-type safety valves, pressure relief valves are installed on this pipe High-Pressure tuabine pipe, which is branched from this pipe to the cold intermediate heat pipe, used when the engine is stopped

Cold re-cooling steam piping: starting from the outlet of the high-pressure tuabine to the inlet of the re-heater, the high-pressure turbine branch pipe is connected to this pipe This tube and its use vary according to the purpose in the factory

Hot re-steam steam piping: starts the re-heater to the inlet valve of the medium pressure turbine, the safety valves of the re-heater outlet are located on this pipe High-pressure steam jetting pipe: High-pressure water jets from a common nozzle of

a boiler feed-water pump to mufflers for heating elements

Reducing heat modulating spray pipe: equivalent to an intermediate level of pressure water supply hose Spray for re-modulating steam can only be used in emergencies or transitional periods

low-Self steam piping: low-Self-powered steam piping that provides steam for oil heaters, steam air dryers, to spray oil mist from nozzles, for coal mills, connected from a road cold re-heat pipe To start, the used steam will be supplied from the auxiliary furnace

Dust blowing pipe: The dust blower is extracted from the pipe connecting to the inlet

of the final superheater to supply steam for the boiler exhaust and air dryers The steam supplied to the air blower's dust blowers is taken from a self-powered steam pipe The condensed water during the hot-air drying of the steam pipe will be discharged to a standing water tank located in the boiler area

2.1.7 Combustion System

The smoke system is used to direct the smoke to the water heaters, heat recovery air dryers, electrostatic precipitators, and sulfur eliminator to take advantage of the excess heat in exhaust fumes, which saves fuel

Wind system: includes level 1 wind system and level 2 wind system Level 1 wind system ensures hot air demand for drying coal in the mill and transporting coal to burners, wind system level 2 ensure most of the hot air in the furnace to burn coal

2.1.8 Air Heater

Air heater is used as a heat recovery type, which is widely used in thermal power plants, the air dryer will reuse the exhaust heat as smoke to provide heat for drying gas to a certain temperature before being used in the oven for use

2.1.9 Coal Mill System

10

Figure 2.3 Coal mill

To ensure that the system can operate stably, the coal will be crushed to a fineness equivalent to 200 mesh (according to ASTM standards) over 90%, and the temperature of the product from the mill reaches 110 degC

2.1.10 Boiler Discharge System

Boiler discharge system has a function:

• Discharge water of steam drum water in an emergency

• Constantly draining a small amount of boiler water to maintain boiler water quality

• Discharge the residue in the furnace through the exhaust line periodically

• Discharge air and non-condensing gases from the water and steam system of the boiler generated during filling and starting up

2.1.11 Dust Blowing System

Dust blowing system will be equipped to clean the heat transfer surface of the furnace, avoiding the efficiency of the furnace is reduced The heat transfer surfaces cleaned

by a dust collection system include the upper part of the flame chamber, the superheater, the water heater, the return air dryer

2.2 Industrial Network

2.2.1 Introduction

Industrial communication networks or industrial networks are a common concept for digital communication networks, serial bit transmissions, used to pair industrial devices Common industrial communication systems now allow network

11

connectivity at various levels, from sensors, actuators at the field level to control computers, observation devices and other computers that are used to run the businesses or manage companies

2.2.2 Advantages of Using Industrial Network

There are many advantages of using industrial network which is presented below:

• A single line: This simplifies the topology between industrial devices

• Saving wires to reduce installation and design cost of the systems

• Improving the reliability and accuracy of the system

• Improving the flexibility of system

• Simplify / facilitate parameterization, diagnostics, fault locating, and shooting of devices

trouble-• Opening up many new functions and applicability of the system: Using industrial communication networks to allow the application of new control architectures such as distributed control, distributed control with field devices, control systems, remotely monitor or diagnose faults via the Internet, integrate information of control and monitoring systems with production management and company

management information

2.2.3 Hierarchical Levels in Industrial Communication Networks

Industrial networks may be classified in several different categories based on functionality - field-level networks (sensor, actuator or device buses), control-level networks (control buses) and information-level networks

12

a) Field Level

The lowest level of the automation hierarchy is the field level, which includes the field devices such as actuators and sensors The elementary field devices are sometimes classified as the element sublevel The task of the devices in the field level is to transfer data between the manufactured product and the technical process The data may be both binary and analog Measured values may be available for a short period of time or over a long period of time

Field-level industrial networks are a large category, distinguished by characteristics such as message size and response time In general, these networks connect smart devices that work cooperatively in a distributed, time-critical network They offer higher-level diagnostic and configuration capabilities generally at the cost of more intelligence, processing power, and price At their most sophisticated, Fieldbus networks work with truly distributed control among intelligent devices like FOUNDATION Fieldbus Common networks included in the device bus and Fieldbus classes include CANOpen, DeviceNet, Profibus-DP, and SDS…

Nowadays, the Fieldbus is often used for information transfer in the field level Due to timing requirements, which have to be strictly observed in an automation process, the applications in the field level controllers require cyclic transport functions, which transmit source information at regular intervals The data representation must be as short as possible to reduce message transfer time on the bus…

b) Control Level

At the control level, the information flow mainly consists of the loading of programs, parameters, and data In processes with short machine idle times and readjustments, this is done during the production process In small controllers,

it may be necessary to load subroutines during one manufacturing cycle This determines the timing requirements It can be divided into two: cell and area sublevels

• Cell Sublevel

For the cell level operations, machine synchronizations and event handlings may require short response times on the bus These real-time requirements are not compatible with time- excessive transfers of application programs, thus making an adaptable message segmentation necessary

In order to achieve the communication requirements in this level, local area networks have been used as the communication network After the introduction of the CIM concept and the DCCS concept, many companies developed their proprietary networks for the cell level of an automation system The Ethernet together with TCP/IP (transmission control

protocol/internet protocol) was accepted as a de facto standard for this level,

though it cannot provide a true real-time communication

• Area Sublevel

The area-level consists of cells combined into groups Cells are designed with application-oriented functionality By the area level controllers or process operators, the controlling and intervening functions are made such as the setting of production targets, machine startup and shutdown, and emergency activities

We typically use control-level networks for peer-to-peer networks between controllers such as programmable logic controllers (PLCs), distributed control systems (DCS), and computer systems used for human-machine interface (HMI), historical archiving, and supervisory control We use control buses to coordinate and synchronize control between production units and manufacturing cells Typically, ControlNet, PROFIBUS-FMS and (formerly) MAP are used as the industrial networks for controller buses Besides, w e can frequently use Ethernet with TCP/IP as a controller bus to connect upper-level control devices and computers

c) Information Level

The information level is the top level of a plant or an industrial automation system The plant level controller gathers the management information from the area levels, and manages the whole automation system At the information level there exist large scale networks, e.g Ethernet WANs for factory planning and management information exchange We can use Ethernet networks as a gateway to connect other industrial networks

2.2.4 Industrial Communication Networks of ALLEN BRADLEY

Communication networks are described based on certain protocols A protocol

is a set of rules used in the communication between two or more devic es Based

on these protocols, communication networks are classified into several levels and different types as figure bellow:

14

Figure 2.5 Structure of Allen Bradley network

a Ethernet Industrial Network

EtherNet/IP provides users with the network tools to deploy standard Ethernet technology (IEEE 802.3 combined with the TCP/IP Suite) for industrial automation applications while enabling Internet and enterprise connectivity…data anytime, anywhere [1] Besides, it supports for the interchange of large amounts of information and communication over a wide range The communication processors used in the network always check to see if the link is occupied

Figure 2.6 Ethernet/IP network connection structure

EtherNet/IP offers various topology options including a conventional star with standard Ethernet infrastructure devices or device level ring (DLR) with EtherNet/IP devices so enabled Quick Connect functionality allows devices

to be exchanged while the network is running Compliance with IEEE Ethernet standards provides users with a choice of network interface speeds — e.g., 10,

100 Mbps and 1 Gbps — and a flexible network architecture compatible with commercially available Ethernet installation options including copper, fiber, fiber ring, and wireless In EtherNet/IP networks, the exchange of data is based

on the producer/consumer model where a transmitting device produces data on the network and many receiving devices simultaneously consume this da ta Traffic generated during data exchange can include input/output data and status produced by a remote device for consumption by one or more programmable controllers Options for industrially rated devices incorporating IP67-rated connectors with module and network status LEDs with device labeling provides ease of use

b DeviceNet

DeviceNet is a digital, multi-drop network that connects and serves as a communication network between industrial controllers and I/O devices, providing users with a cost-effective network to distribute and manage simple devices throughout the architecture [1] DeviceNet utilizes CAN (Controller Area Network) for its data link layer, the same network technology used in automotive vehicles for communication between smart devices

DeviceNet uses a trunkline-dropline topology and has DC power available on the network cable to simplify installations by providing a single connection point for network communications and device power up to 24 Vdc, 8 Amps QuickConnect functionality allows devices to be exchanged while the network is running In addition, DeviceNet operates in a master-slave or a distributed control architecture using peer-to-peer communication, and it supports both I/O and explicit messaging for a single point of connection for configuration and control

16

Figure 2.8 ControlNet connection structure

The DeviceNet communication network has a trunk and branch network structure, the maximum number of nodes is 64 The length of the backbone and the type of cable determining the transmission speed of the DeviceNet network is shown at the table below:

Table 2-1 Type of Devicenet cable

Note: Overall, Ethernet is great for data collection, transmission and monitoring, and

can provide information technology personnel the information they need Contrary, DeviceNet is best suited for collecting and managing the I/O data the machine and process control systems need Most advanced automation architectures need both data and control networks to run well

d Modbus

Figure 2.9 Modbus connection structure

Figure 2.10 Transfer data between multiple controller

Modbus protocol is an opening system protocol that can run on many different physical layers It is the most widely used protocol in industrial control applications

It can be done on any transmission medium, but is often used with RS232 and RS485

Modbus serial with RS232 or RS484 facilitates the connection of Modbus devices with controllers (such as PLCs) in the bus structure It can communicate between a master and 247 slaves with a data transfer rate is 19,2kbits / s

2.3 Transfer Data Based On Produced Tag And Consumed Tag Protocol

Produced tag: A tag that a controller makes available for use by other controllers Multiple controllers can simultaneously consume (receive) the data A produced tag sends its data to one or more consumed tags (consumers) without using logic

Consumed tag: A tag that receives the data of a produced tag The data type of the consumed tag must match the data type (including any array dimensions) of the produced tag The RPI of the consumed tag determines the period at which the data updates

For multiple controllers to share produced or consumed tags, both of them must be in the same backplane or attached to the same control network, such as ControlNet or

18

Table 2-2 Exchange data between PLCs

EtherNet/IP network Although produced and consumed tags can be bridged over two networks, Rockwell Automation does not support this configuration

PLC series can exchange data based on Produced and Consumed Tag protocol via controlnet and ethernet communication networks are shown as table below:

Produced and consumed tags each require connections As the number of controllers that consume a produced tag increases, the number of connections the controller has available for other operations, such as communication and I/O, decreases

Using one of the data types like Real, Dint, Array of Dint or Real The size limit of a standard tag is 500 bytes If exchanging data over the ControlNet network, the tag size is less than 500 bytes

2.4 Allen Bradley PLC Series

a) PLC-5 Controllers

The PLC-5 family has been around since 1986 and was Rockwell’s flagship PLC system until the late 90’s The PLC-5 is a powerful controller housed in a heavy-duty metal enclosure It has built-in communication adapters on the controller to allow it

to communicate with remote input and output modules The type of built-in communication adapters on the PLC-5 vary depending on the processor model These communication adapters would be ControlNet, EtherNet/IP or DH+/Remote I/O The PLC-5 family is programmed with RSLogix 5 Rockwell Automation/Allen-Bradley is phasing out the PLC-5 since the ControlLogix PAC has taken its place with much more power, flexibility and a much more user-friendly programming software

b) SLC 500 Controllers

The SLC 500 family was introduced in 1991 and was intended to be a more economical solution than the PLC-5 that could be used for smaller or less complex applications With the SLC 500 controllers a slightly modified programming software called RSLogix 500 which also used for their MicroLogix PLC family Even with today’s standards it performs very well for most applications, but it too is being phased out in favor of newer technology

ControlLogix Controller is The ControlLogix family that was introduced in 1997 It

is still Rockwell’s flagship control system and although it has undergone several version changes and upgrades over the years, it is still basically the same platform The ControlLogix controllers are very powerful processors and are far more configurable than all the other A-B PLCs Even the base level processor 1756-L71 is more powerful and has more program and I/O capacity than the largest PLC-5 processor One of the unique features of ControlLogix is that a processor can be placed in any slot of the chassis and there can be multiple processors in one chassis The ControlLogix processors are programmed with RSLogix 5000 (now Studio 5000 Logix Designer)

c) CompactLogix Controllers

The CompactLogix system was released in the early 2000’s with a similar purpose to the older SLC 500: to be a more affordable solution for simpler applications that did not require the advanced capabilities of the more expensive ControlLogix system The CompactLogix has taken the place of SLC 500 as the cost-effective small control system of choice CompactLogix processors are programmed with RSLogix 5000/Studio 5000 Logix Designer This is good news for A-B PLC programmers because we only need to be familiar with one software platform to program

d) CompactLogix or ControlLogix systems

There are several types of CompactLogix Controllers, including several recently added controllers Some of the new controllers have some basic built-in I/O for the very simple where you just want a small processor and some basic I/O all in one package All the CompactLogix processors have built-in Ethernet cards which eliminates the cost of the external Ethernet modules needed for ControlLogix processors

2.5 Overview About SCADA System

2.5.1 SCADA System Components

A SCADA system usually consists of the following main elements: [3]

20

• Supervisory computers

This is the core of the SCADA system, gathering data on the process and sending control commands to the field connected devices It refers to the computer and software responsible for communicating with the field connection controllers, which are RTUs and PLCs, and includes the HMI software running on operator workstations In smaller SCADA systems, the supervisory computer may be composed of a single PC, in which case the HMI is a part of this computer In larger SCADA systems, the master station may include several HMIs hosted on client computers, multiple servers for data acquisition, distributed software applications, and disaster recovery sites To increase the integrity of the system the multiple servers will often be configured in a dual-redundant or hot-standby formation providing continuous control and monitoring in the event of a server malfunction or breakdown

• Remote terminal units

Remote terminal units, also known as (RTUs), connect to sensors and actuators in the process, and are networked to the supervisory computer system RTUs are "intelligent I/O" and often have embedded control capabilities such as ladder logic in order to accomplish boolean logic operations

• Programmable logic controllers

Also known as PLCs, these are connected to sensors and actuators in the process, and are networked to the supervisory system in the same way as RTUs PLCs have more sophisticated embedded control capabilities than RTUs, and are programmed in one

or more IEC 61131-3 programming languages PLCs are often used in place of RTUs

as field devices because they are more economical, versatile, flexible and configurable

• Communication infrastructure

This connects the supervisory computer system to the RTUs and PLCs, and may use industry-standard or manufacturer proprietary protocols Both RTU's and PLC's operate autonomously on the near-real time control of the process, using the last command given from the supervisory system Failure of the communications network does not necessarily stop the plant process controls, and on the resumption of communications, the operator can continue with monitoring and control Some critical systems will have dual redundant data highways, often cabled via diverse routes

• Human-machine interface

The human-machine interface (HMI) is the operator window of the supervisory system It presents plant information to the operating personnel graphically in the form of mimic diagrams, which are a schematic representation of the plant being controlled, and alarm and event logging pages The HMI is linked to the SCADA supervisory computer to provide live data to drive the mimic diagrams, alarm displays, and trending graphs In many installations, the HMI is the graphical user interface for the operator, collects all data from external devices, creates reports, performs alarming, sends notifications, etc

2.5.2 The Functions of SCADA Systems:

SCADA systems perform several functions The three basic functions are the monitoring, control and user interface functions:

• The monitoring function collects data and sends it back to the central computer

• The control function gathers data from monitoring sensors, processes it and sends control signals back to the equipment according to a prescribed software program

• The user interface is often a large control room where individuals can monitor SCADA input and output responses in real-time.[3]

2.5.3 Hardware and Software of SCADA System:

The hardware depends on the manufacturer, SCADA systems will have a number of different characteristics, but SCADA hardware still includes some basic components:

• PC with standard communication services and pre-designed graphical interface programs

• Programmable logic controllers

• Transmitter / RTU

• Network card and attached cable system for collection and control [3]

The software now has a lot of specialized software to implement a SCADA system

of different brands such as FactoryTalk View Site Edition, Rsview32 of Rockwell Automation, WinCC, TIA Portal of Siemens, MC Works64 of Mitsubishi FactoryTalk View Studio is a software suite for developing HMI applications in the

"integrated architecture" of Rockwell Automation This toolkit is used for all Rockwell's "view" related applications, from the Panelview Plus operating screens to multiple SCADA Server / Client systems This is convenient because users do not have to install many different software, switching back and forth between HMI applications Moreover, FactoryTalk View uses the same FactoryTalk platform, so sharing and exchanging data with other software is also very easy and convenient