Industrial Control System for Boiler of Crude Oil Unit - Report Example

Industrial control system for Boiler of crude oil unit Customer to Insert His/her Name Customer to Inserts Grade course Customer Insert Tutors Name 29.10.2014 Executive Summary The report was specifically to develop control unit that regulates catalyst, temperature, power supply, flow rate, amplitude and frequency; examine the step changes on integral value disturbance and bandwidth with the voltage output of a boiler to avoid corrosion that leads to failure that is expensive. This project was evaluated and found to be cost effective when coordinating and controlling functions. Its ability to coordinate with the desired catalysts entry and power supply was investigated, how the process could be made more effective from the controller point of view was important, it was therefore mandatory when investigating this to apply control measures, and such effects of introducing any step changes on parameters like temperature, the effects of integral actions on the system’s response was key too. This would also ensure other dependable functional parameter is highly maximized. If the bandwidth is increased, it leads to a deviation in the mains voltage, comparison of these findings to the manufacturer directives as per the manual specifications was important to arrive at the conclusive parameter combinations that gave an ample specification that were not only environmental friendly but also safe for the people carrying out the exercise. Introduction When boilers fail is due to elements which have low percentage of corrosion resistance metals or metal that is not pure. These metals act as anode and cathode thereby allowing electrochemical reaction which leads to reaction. They are other form of corrosion whereby there is overloading of conditions and materials such as temperature, pressure, and flow rate which leads to corrosion of the boiler. If the boiler is made of stainless steel is used and oil contains alumina there are high chances of reaction which will lead to corrosion. In this case the remedy is to design a system to detect catalyst material from entering the boiler. When the boiler is made of carbon steel and the temperature exceeds 90 degrees together with the reactant the erosion will take place. Because temperature is critical in reaction, the last form of corrosion is microbiological corrosion which is as a result of micro-organism. In this paper we will set and design a control system which will detect the entry of catalyst into the boiler and it closes off. The system to be designed will be attributed control system which gathers the information and controls the system on a large scale based on a very band width. This controlled process system achieves its control of substances entering the boiler by ensuring both the feedback and feed forward looks are deployed automatically within a specified time interval. In the crude oil boiler this system will be tested in a controlled manner to ensure that it performs efficiently. It is a programmable logic controller which ensures that the system works efficiently. The system will lead to control of temperature, power supply, flow rate, amplitude and frequency; examine the step changes on integral value disturbance and band width with the voltage output. The system uses an open loop control. Its remote terminal units would ensure that the supervisory data are send back to its control stations. Such systems must be integrated with a computer to rely the data that can be interpreted by the in build software. Such controlled processes have not only made some work easier to manage and get a real time results but has also saved a lot on several modalities that would have complicated the entire process and hence increasing the applicable cost of running very simple processes. Methodology The set up uses a PT 326 feedback process Trainer and PCS 327 process controller, which uses a self contained process of simulation with an inbuilt controller function, this was carried out by the PCS 327 which was connected to both sockets A and socket B on the PT 326, socket B was to send deviation induced on the machine to the PCS 327, while socket A received a signal that was to convert the electrical power to the heater. An additional socket C was meant to modify the received signals. . In this experimental set up, the method that was utilised involved altering parameters under investigations and measuring their corresponding effects on the temperature changes, these were then compared with the set values so at to generate a control signal that could enable regulation of the electrical power supply to heaters. The justifications for this industrial control process is based on the fact that most if not all industrial processes require energy utilization, but of late these have become so expensive that maximum utilization has become a key consideration. There is a need to therefore formulate ways and methods of ensuring such processes attain maximum utilization of the available resources at a controlled approach. Heating applications is the generation and transfer of heat as well as its regulation within set limits to avoid loss of this precious energy. Such settings would more often give a better combination of various parameters under investigations that could be unified to give the best result in any controlled industrial process. Cost-Benefit analysis Investment Boiler modifications 200,000 Catalyst detector 340,000 Temperature and pressure detector 170,000 Control valves 103,500 Total investment 813,500 Addition annual operating cost 75000 Boiler service and breakdown Additional annual electricity bill 70150 Total additional operating cost per annum 145,150 Annual saving 252,000 Total saving per annum 106,850 Saving on boiler repair after every two years 16,575 Duration of the of the project is 10 years For appraising the investment project given, the payback period technique has been applied as under to determine whether the design should be undertaken. Initial investment 813,500 1st years and 2nd years (2x 106 850) 213700 Saving on boiler repair after every two years 16,575 3rd years and 4th years (2x 106 850) 213700 Saving on boiler repair after at 4th year 16,575 5th years and 6th years (2x 106 850) 213700 Saving on boiler repair after at 4th year 16,575 7th years 106 850 797,675 15,825 Pay back period = 7 years + 7.13 years In accordance with the payback period appraisal technique, the initial investment is expected to be paid back after 7.13 years. Therefore, on these bases, it is recommended that the system shall be designed. Discussion of results These designs were subdivided in seven areas that cause corrosion these were; catalyst control, the flow rates, power, bandwidth change, stepwise control, and temperature changes. From the first set up involving the flow rate, results show a significant variation in the functional deduction. In the first part, where the flow rate is compared with power and temperature, the flow rate increased when a certain minimum temperature was kept constant, while the maximum temperature declined linearly at a constant power. When the flow rate is maintained at a constant value, minimum temperature rose steadily before it started declining while the maximum temperature declined steadily until it levelled with the minimum temperature. In the flow rate 4 the maximum attained rate for both the channels, the channels gave reverse figures, and because at no one point did they gave uniform result. These representations however gave a bigger margin in between the settings that were being investigated. The second set up the variables gave a better result only inferior to the first example above. Other set up herein referred to as the flow rate 2, whose variation were almost constant; the preceding representations did not have such kind of representation. The most notable and observable difference is that the figures gave a less difference in these variations, smaller than the previous two. This showed an improved efficiency in not only timing but also giving the output of required variable. Similar results to this setting were obtained in the sixth experiment within the flow rate, although the highest variable was achieved at positive nine, another difference is the presence of a wider gap between the functions that represents the utility of the applied variables under control and comparison. In the fifth set up, the functional variables that were examined were also more dependent on each other than in the previous experiments, the gap between the functional variations do indicates a more dependent and significant adaptations upon alteration to effect the changing parameters. The last setting stands out because the variables that were investigated did not predict steadiness as expected. These wide differences in the aftermath produced a more unpredictable representation. From the power design, several designs are carried out. The first setup, a constant variation was seen on channel A, while B gave a slight noticeable drift; these kept varying by going down until a maximum value was recorded. In Power 0.4, a steady and more variable characteristic was witnessed; this stood out from the first case because there were no variations from the set targets upon which the values had to range within. In the set up named power 1 which assumed a more or less steady distribution and showed a steady variation between the experimental variables, the maximum value ranged within 8452 graphical value. From this the least recorded variation between the two was noted at around -9.5. Finally, the last arrangement of this part of the experiment gave a good variation with only two instances seen at around 10330 and 2818 that were not in line with the expectation. This alludes that these variables can be combined and monitored at a certain interval and controlled to ensure the correct values are fully utilized. From the experiment on temperatures and the bandwidth, an increase in temperatures lead to a decline in the proportional bandwidth, at proportional bandwidth 40, we sees a drift in both A and B, they took a uniform drifting. The maximum value for B was much more than that for A, the opposite is true for the lowest value recorded where the minimum for A was lower than that for B. For the positive or negative variable, B was on the positive scale, therefore gave positive value while A was below the X- axis, this gave a negative value in the entire experiment. In experiment at proportional bandwidth 60, maximum for B was 5.5, while for A was 1.8. The experiment gave similar graphical representation as the previous one, because B variables gave positive value as opposed to A which gave negative values. However, these variations were on a linear scale. Perhaps, the value for A is the lowest for the entire experimental set up. For experiment at proportional bandwidth 80, the maximum B value recorded was 4.3 against A which was 0. The minimum value for B was -1 while for A it was noted as -3. Equally, these variables were distinct because A gave a negative value as opposed to B, which is a positive variable. In at proportional bandwidth 100 experiment, the highest attainable variable for B was 40, while A is 0; the minimum variables recorded for B was-8 while -3 for A. In this case B gave a lesser variable than A contrary to other settings. These variables varied uniformly along the scale and could be easily controlled to give a desired function in a processing industry. In experiment at proportional bandwidth 120, the maximum recorded value for B was 3.8 while -2, was the minimum. A gave a maximum of -2 and a minimum of -6. Conclusions Findings indicated that maximizing power usage will depend on overlap mechanisms that are laid in place to ensure regulated temperature is kept within the required range. Such alterations have been found to be instrumental in making the plants effective, safe and environmental friendly for the people carrying out the exercise in the processing plant. A steady deviation in the mains voltage was brought by a decrease in the bandwidth, equally. A rise in efficiency value of the controller was witnessed due to a decrease in energy produced; this was reflected in an increased flow rate. Comparison of these findings to the manufacturer directives as per the manual specifications was important to arrive at the conclusive parameter combinations that gave an ample specification for the various variables. Read More

Cost-Benefit analysis Investment Boiler modifications 200,000 Catalyst detector 340,000 Temperature and pressure detector 170,000 Control valves 103,500 Total investment 813,500 Addition annual operating cost 75000 Boiler service and breakdown Additional annual electricity bill 70150 Total additional operating cost per annum 145,150 Annual saving 252,000 Total saving per annum 106,850 Saving on boiler repair after every two years 16,575 Duration of the of the project is 10 years For appraising the investment project given, the payback period technique has been applied as under to determine whether the design should be undertaken.

Initial investment 813,500 1st years and 2nd years (2x 106 850) 213700 Saving on boiler repair after every two years 16,575 3rd years and 4th years (2x 106 850) 213700 Saving on boiler repair after at 4th year 16,575 5th years and 6th years (2x 106 850) 213700 Saving on boiler repair after at 4th year 16,575 7th years 106 850 797,675 15,825 Pay back period = 7 years + 7.13 years In accordance with the payback period appraisal technique, the initial investment is expected to be paid back after 7.13 years. Therefore, on these bases, it is recommended that the system shall be designed.

Discussion of results These designs were subdivided in seven areas that cause corrosion these were; catalyst control, the flow rates, power, bandwidth change, stepwise control, and temperature changes. From the first set up involving the flow rate, results show a significant variation in the functional deduction. In the first part, where the flow rate is compared with power and temperature, the flow rate increased when a certain minimum temperature was kept constant, while the maximum temperature declined linearly at a constant power.

When the flow rate is maintained at a constant value, minimum temperature rose steadily before it started declining while the maximum temperature declined steadily until it levelled with the minimum temperature. In the flow rate 4 the maximum attained rate for both the channels, the channels gave reverse figures, and because at no one point did they gave uniform result. These representations however gave a bigger margin in between the settings that were being investigated. The second set up the variables gave a better result only inferior to the first example above.

Other set up herein referred to as the flow rate 2, whose variation were almost constant; the preceding representations did not have such kind of representation. The most notable and observable difference is that the figures gave a less difference in these variations, smaller than the previous two. This showed an improved efficiency in not only timing but also giving the output of required variable. Similar results to this setting were obtained in the sixth experiment within the flow rate, although the highest variable was achieved at positive nine, another difference is the presence of a wider gap between the functions that represents the utility of the applied variables under control and comparison.

In the fifth set up, the functional variables that were examined were also more dependent on each other than in the previous experiments, the gap between the functional variations do indicates a more dependent and significant adaptations upon alteration to effect the changing parameters. The last setting stands out because the variables that were investigated did not predict steadiness as expected. These wide differences in the aftermath produced a more unpredictable representation. From the power design, several designs are carried out.

The first setup, a constant variation was seen on channel A, while B gave a slight noticeable drift; these kept varying by going down until a maximum value was recorded.

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