Operation Ability Improvement of Mini Plant Boiler BDT921 with Controller Migration from Single Loop Controller (SLC) to Programmable Logic Controller (PLC)

• Main Author: Dzakwan Afif Fadhullah, M
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/39355
• Institution: Institut Teknologi Bandung

A Mini plant Boiler model BDT921 was one of the operator training facilities for controlling a process system, especially a Boiler. However, the mini plant was still used a Single Loop Controller (SLC) which was considered quite a limitedness to operate, such as there is no data recording from the process, fixed control scenario from the manual book, and not compatible to be integrated with HMI. At the operating document of SLC, there is no standard P&ID based at ISA 5.1 and had very complicated operating scheme in the document. So a controller migration is needed to increase the operation pattern of the mini plant. The solution was chosen to migrate the Single Loop Controller (SLC) to Programmable Logic Controller (PLC), so the mini plant system could have a better control action. This is based on the PLC that could have more advantage features than the SLC, such as the ability to record the data. In addition, PLCs can be integrated with other systems to support existing mini plant operations. The results from this system are the finished programming system for process control purposes at mini plant Boiler BDT 921 with using Ladder programming at Allen-Bradley SLC-500 PLC and then integrated it with HMI using OPC Client Server. Other than that, with the presence of High-Performance HMI is to make the system operated as good as possible for the user. Then with the data recording system/historian database, it could make the system to be recorded and saved for further analysis requirement. After the system was integrated well, justification from the system was needed to ensure the response from the system is theoretically proven. The justification is made with testing, modelling, and simulation from various configurations at each control loop. There is four control loop in this system, such as loop control of flow rate to Boiler, loop control of level at Boiler, loop control of flow rate to Heat Exchanger, and loop control of product temperature from the Heat Exchanger, in which all of the control loops is do various of scenario to change the PID parameter and vary the control strategy, such as simple feedback, cascade control, feed forward control, and adaptive control. So as the system is well built and had been justified from the performance test, the system was expected to make the operation and control system from the mini plant was increased.