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Centralised Automation and Control System

How a Centralised Automation and Control System Improves Plant Efficiency

| Author / Editor: Saurabhi Chitnis / Marion Henig

The challenge

Project managers at RRB knew that they needed a ‘systems‘ integrator’ to develop and implement the automation and control system, and they turned to Control and Solutions India Limited (CSIL).

CSIL was chosen because they specialise in automation and control systems for the process industries, building automation and substation automation. After reviewing the existing cogeneration system, CSIL provided RRB several options for a centralized system — that would meet their requirements. Ultimately, RRB selected an InduSoft Web Studio-based HMI/SCADA system with Honeywell PID loop controllers.

The boiler control has many useful features that have made the process much more manageable. For example, it reads boiler process parameters from primary sensors and secondary instruments, which helps RRB control critical points in the process. The system also controls threshold deviations and activates alarms if thresholds are breached. History data logging is built into the system and a browsing feature provides access to the logs for a complete history of the operation.

Designed for Microsoft Windows environments, InduSoft Web Studio uses open technologies to connect to monitoring and control hardware and third-party software applications. Honeywell’s PID controllers are based on open technology and were easily networked to the InduSoft-based system. To monitor the boiler temperature, temperature scanners were easily integrated into the InduSoft system through a Modbus communication driver. The application collects temperature data from these scanners, displays temperature values on colour graphic screens, and logs the data where it can be used to generate graphs. CSIL and RRB engineers developed the HMI/SCADA applications, which included control algorithms, alarm and reporting systems, and data logging functions.

Thus, a full-featured performance management system was developed and implemented using InduSoft Web Studio’s menu-based Rapid Application Configuration Environment (RACE). The system presents real-time data from the boilers and turbines to the analysing logic, and then downloads appropriate setpoint changes to the PID controllers.

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