NITROGEN PLANT AUTOMATION USING PLC AND SCADA

NITROGEN PLANT AUTOMATION USING PLC AND SCADAROYAL COLLEGE OF ENGINEERING & TECHNOLOGYPresented By: JAMSHEER M I PRANAV RAMACHANDRAN AJEESH V N SUDHEESH SGroup No:9S8 AE&I Guided By: NICY V B Asst. Professor Applied Electronics & Instrumentation 20 April 2016 NITROGEN PLANT AUTOMATION USING PLC AND SCADA1

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OUTLINEDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA2 OBJECTIVE ABOUT COMPANY INTRODUCTION LITERATURE SURVEY NITROGEN PLANT BLOCK DIAGRAM CIRCUIT DIAGRAM HARDWARE DESCRIPTION FLOW CHART SOFTWARE DESCRIPTION

OUTLINEDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA3 PLC IMPLEMENTATION SOFTWARE DESCRIPTION SCADA IMPLEMENTATION ADVANTAGES CONCLUSION FUTURE WORKS REFERENCE

OBJECTIVEThis project deals with Nitrogen plant automation using PLC and SCADA.Today most of the industrial processes are controlled by the use of PLC.The PLC is a digital computer used for automation of electromechanical process such as Control of machinery on factory assembly lines, Amusement rides, Light fixtures etc.DEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA4

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OBJECTIVEDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA5The automation process of the system consists of the following hardware such as Solenoids valves Air compressor Air filter regulator Rotameter Bourdon tube Pressure switch etc.

ABOUT COMPANYThe Travancore Cochin Chemicals Limited (TCC), Udyogamandal is a State Public Sector Undertaking owned by Government of Kerala.TCC has a good track record of profitable operation and healthy industrial relations. It is a heavy chemical industry engaged in the manufacture and marketing of Caustic Soda, Chlorine and allied chemicals.

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ABOUT COMPANYIt is the only caustic soda producing plant inKerala.Now TCC plant ready to make chemical for rocket fuel.This plant will produce five tons of sodium chlorate per day.DEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA7

INTRODUCTIONThis project deals with Nitrogen plant automation using PLC and SCADA.Nitrogen is produces from the air taken from the atmosphere.Atmospheric air with various impurities admitted and compressed through air compressor and send to an air receiver, then to the system. Plant has two tanks of similar capacity.First tank works for 40 seconds mean while the second one regenerates.

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LITERATURE SURVEYSEPARATION OF NITROGEN FROM AIR BY SELECTIVE ADSORPTION OF CARBON MOLECULAR SIEVES AUTOMATION OF NITROGEN PLANT USING PSA TECHNOLOGYNITROGEN PLANT AUTOMATION USING PLC AND SCADA

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LITERATURE SURVEYPAPER-1SEPARATION OF NITROGEN FROM AIR BY SELECTIVE ADSORPTION OF CARBON MOLECULAR SIEVES (V. STANCIU) Prof., Dept. of Physics, Ferdinand I High SchoolThe paper show the data obtained when air Nitrogen is enriched by using experimental PSA system in two variantsSeparation principle is based on the difference between Oxygen and Nitrogen adsorption speed on CMS.

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LITERATURE SURVEYPAPER-2AUTOMATION OF NITROGEN PLANT USING PSA TECHNOLOGY (ASHA JOHN)Assistant Professor, Jyothi Engineering College, Thrissur, Kerala, IndiaThis paper mainly highlights with the manufacture and control of Nitrogen in plant automation using PLC.A Programmable logic controller (PLC) is a digital computer used or automation of electromechanical processesDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA11

LITERATURE SURVEYPAPER-3NITROGEN PLANT AUTOMATION USING PLC & SCADA (ASHA JOHN) Assistant Professor, Jyothi Engineering College, Thrissur, Kerala, IndiaThis paper deals with Nitrogen plant automation using PLC and SCADA .SCADA (supervisory control and data acquisition) is a type of industrial control system (ICS).

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NITROGEN PLANT BLOCK DIAGRAM

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CIRCUIT DIAGRAM

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HARDWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA15AIR COMPRESSORIt is a device that converts from power usually from an electric motor, a diesel engine or a gasoline engine in to kinetic energy by compressing and pressurizing air.The numerous methods of air compression divided in to eitherPositive displacement type. Negative -displacement type.

HARDWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA16

Fig: Reciprocating air compressor

HARDWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA17AIR RECIEVER TANKAir receivers tanks are used for compressed air storage and are recommended to be in all compressed air systems.Usually air receivers of unsound or questionable construction can be very dangerous.

Fig: Air receiver tank

HARDWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA18PRESSURE SWITCHIt is a form of switch that closes an electrical contact when a certain set pressure has been reached on its input. A pressure switch for sensing fluid pressure contains a capsule, bellows, bourdon tube, diaphragm etc.It displaces proportionally to the applied pressure.The resulting motion is applied, either directly or through amplifying levers, to a set of switch contacts.

HARDWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA19TOWER-1 & TOWER-2 OR PSA UNIT There are 2 towers filled with special grade CMS (Carbon Molecular Sieves) to absorb O2 , CO2 & moisture present in the air.Each tower has air inlet valve bottom, gas outlet valve at top and exhaust outlet valve at middle.The air inlet line from air receiver has a global valve to control the flow of air.So that the maximum pressure in the PSA (Pressure Swing Adsorption) or absorbing tower is 7 Kg/cm^2.

HARDWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA20

Fig: Carbon Molecular Sieve

HARDWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA21Pressure Swing Adsorption(PSA)It is a technology used to separate some gas species from a mixture of gases under pressure according to the species of molecular characteristics and affinity for an adsorbent material.Specific adsorptive materials (e.g.,zeolites,activated carbon, Carbon Molecular Sieves (CMS) etc.) are used as a trap, preferentially adsorbing the target gas species at high pressure.

HARDWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA22NITROGEN SURGE VESSELThe surge vessel gives nitrogen at constant pressure with a constant average purity.Nitrogen from Pressure Swing Adsorption (PSA) unit will have varying purity in 1 minute cycle time. OXYGEN ANALYSERAn online oxygen analyzer continuously monitoring oxygen percentage in surge vessel.Whenever oxygen percentage above the set value, vent valve open.

HARDWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA23NITROGEN STORAGE TANKA nitrogen storage tank is installed for storage of nitrogen gas at pressure of 5 Kg/cm^2.Two manual valves are provided at inlet and outlet of tank.When the pressure of gas in the tank exceeds 5Kg/cm^2, the plant is made to trip using high pressure switch.

FLOWCHART DEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA24

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SOFTWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA25PROGRAMMABLE LOGIC CONTROLLER (PLC) It is an industrially hardened computer-based unit that performs discrete or continuous control functions in a variety of processing plant and factory environments. Originally indented as relay replacement equipment for the automotive industry.

PLC IMPLEMENTATIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA26RS Logix500 It save project development time, and improve productivity.This family of products has been developed to operate on Microsoft Windows operating systems.It supporting the Allen-Bradley SLC 500 and MicroLogix families of processors.RSLogix 500 was the first PLC programming software to offer unbeatable productivity with an industry-leading user interface.

PLC IMPLEMENTATIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA27RS-Linx RSLinx Classic is the most widely installed communication server in automation today. RSLinx Classic provides plant-floor device connectivity for a wide variety of Rockwell Software applications such as RSLogix 5/500/5000 and RSView32. RSLinx Classic also provides open interfaces for third-party HMI, data collection and analysis packages, as well as custom client-applications. RSLinx Classic supports multiple software applications

PLC IMPLEMENTATIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA28RS Emulate 500 RSLogix Emulate 500 is Microsoft Windows-based software package that emulate one or more PLC-5, SLC 500 processors respectively. RSLogix Emulate scans the ladder logic like an actual processor.

SOFTWARE DESCRIPTIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA29SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) It is a type of industrial control system (ICS). Industrial control systems are computer controlled systems that monitor and control industrial processes that exist in the physical world. SCADA systems historically distinguish themselves from other ICS systems by handling large scale processes that can include multiple sites, and large distances.

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SCADA IMPLEMENTATIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA31The SCADA system was designed with a software package that has helped to ensure future upgrade capability and compatibility. The controlling is being done using mainly 10 types of valves, also consist of receiver tank, surge vessel, and main storage tank.In the given figure, the green colour indicate the flow of nitrogen and the red colour indicates the waste gas. It is implemented using the Software Rockwell Automations RS View 32 for the SCADA, and associated communication tool RSLinx.

ADVANTAGESDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA32Nitrogen generators are efficient in continuous nitrogen supply.The plant is secure and reliable.Easy to operate by using PSA technology.Reduce storage cost.Minimize support and maintenance.Nitrogen purity is high.

CONCLUSIONDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA33This project highlights the process of manufacture and quantity control with the automation process in the industry Nitrogen is valued both as a gas for its inert properties and as a liquid for cooling & freezing.Adsorption and other technologies for air separation continue to advance as more efficient.Increased power efficiency in PSA nitrogen generators is being driven both by process improvements and enhanced adsorption materials.

FUTURE WORKSDEPT. OF AE&IE NITROGEN PLANT AUTOMATION USING PLC AND SCADA34Increased power efficiency in PSA nitrogen generators is being driven both by process improvements and enhanced adsorption materials.A large range of flow and purity combination can be met by adjusting the size of the air compressor and adsorption vessels containing the CMS.

REFERENCESSvetlana Ivanovo, Robert Lewis, Producing Nitrogen via Pressure Swing Adsorption- Reactions and Separations.Memo 3 preliminary design of nitrogen processes: PSA and Membrane systems CARNEGIE MELLONUNIVERSITY CHEMICAL ENGINEERING DEPARTMENT. Retrieved 9 January 2012.http://en.wikipedia.org/wiki/nitrogen_generatorhttp://www.nitrogengenerators.com/ecom.asp?pg=psa-nitrogen-generatorsNitrogen generation by PSA. http://www.linde.com

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THANK YOUAny Questions

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