IndexHeat exchangerFinal control elementsSafety componentsConclusionToday the demand for energy production is increasing. The requirements on control systems are therefore also increasing. In this paper the boiler is operated using many control strategies so that the resulting operation is practically implemented for industrial purposes. In this experiment, the electrically heated boiler and tube-in-tube type heat exchanger are used. Electrically heated boilers use electrical current flowing through a heating element to create heat, to boil water into steam at a high temperature and high pressure. To test improved controllability tube-to-tube, counterflow heat exchanger. During the first phase, the installation, calibration and testing of all transmitters and actuators are completed. Making a system available for the programming of the logic controllers, the distributed control system as well as the simulation software phase. Multiple control purposes are achieved. Pilot plants are controlled using easy-to-use frontends. In this, different control strategies such as PLC, DCS, MATLAB as well as virtual PLCs and DCS with local controllers are used without any compromise in terms of safety. Say no to plagiarism. Get a tailor-made essay on "Why Violent Video Games Shouldn't Be Banned"? Get an Original Essay Automation is the use of machines, control systems, and information technologies to optimize productivity in the production of goods and services. Beyond this is possible with current levels of human labor in order to achieve economies of scale and achieve predictable levels of quality.[10] In the current world of rapid technological changes there is an urgent demand for the best quality products. Automation and simulation of this project is done with the help of PLC. Programmable logic controllers have been an integral part of factory automation and industrial process control.[9] Since we know that energy demands are increasing, unit operations should be managed with a good deal of efficiency and control to save energy and improve the quality and quantity of production. Controllers such as programmable logic controllers, distributed control systems, and simulation tools and test control strategies are available to control pilot plants. We have comparative studies of different classes of control strategies and different classes of controllers. We are having two pilot plants, boiler and heat exchanger. The boiler is electric and operates at a pressure of 3.5 bar at a temperature of 1350°C, providing steam of 30 kg=hour. This steam is used in the heat exchanger which is of the tube-in-tube type and works with counter-current flow of fluids. Both pilot plants are well equipped with industrial-grade transmitters and actuators. The cylindrical body of the boiler contains water which is heated electrically with a PWM controller and generates steam at 4 bar and 144°C. Heating water is pumped from a boiler feed water tank using a positive displacement pump. The constituted boiler body contains water which is heated electrically with a PWM controller and generates steam at 4 bar and 144°C. Heating water is pumped from a boiler feed water tank using a positive displacement pump. The generated steam flows to the heat exchanger through an equal percentage globe valve which controls the steam flow. Since the heat exchanger is of the tubular type incountercurrent, the water to be heated is pumped from a cold water tank at the other end using a centrifugal pump. The condensate that forms in the heat exchanger during heat transfer is collected in a separate condensate tank. The hot water is collected in a hot water tank which can also be mixed into the cold water tank or can be added partially/fully to the boiler feed to change the feed water temperature. A boiler is a closed vessel usually made of stainless steel in which water or other fluid is heated. Electric steam boilers use resistance or immersion heatingelements.Heat ExchangerA heat exchanger is a piece of equipment constructed for efficient heat transfer from one medium to another. The media can be separated by a solid wall, so that they never mix, or they can be in direct contact. There are two main classifications of heat exchangers based on their flow arrangement. In parallel flow heat exchangers the two fluids enter the exchanger from the same end and travel parallel to each other to the other side. In counterflow heat exchangers the fluids enter the exchanger from opposite ends. Sensors and Transmitters The transducer measures a process variable while the transmitter transmits the data to the controller as a 4-20 mA current signal. Final Control Elements The final control element regulates the amount of energy/mass that enters or exits the process as commanded by the controller. The following are the final control elements used in the system:a. Positive displacement pump for boiler feed water supply: the engine speed and, accordingly, the feed flow are changed using a frequency converter.b. Centrifugal pump for supplying cold water to the heat exchanger: the speed of the motor and, accordingly, the feed flow are changed using a frequency converter.c. Equal percentage globe control valve for manipulation of steam flow current signal from the controller is converted into pneumatic signal using an I/P converter which decides the opening of the valve.d. 2-position solenoid valve (open or closed): opening the valve allows mixing of hot water with cold water supplied to the heat exchanger, as well as changing the temperature of the boiler feed water. Safety Components These components ensure process safety which generally refers to the prevention of inadvertent releases of chemicals, energy or other potentially hazardous materials (including steam) during the course of the process which can have serious effects on the plant and the environment. Process safety involves, for example, the prevention of leaks, spills, equipment malfunction, overpressures, overtemperatures, corrosion, metal fatigue and other similar conditions. The following tools are included to keep process variables within safe limits and provide interlock alarms to automatically take necessary actions:a. Pressure switch and heat switch: Turns off the boiler if the drum pressure/temperature exceeds 4 bar/144 degrees Cb Low level switches: For the boiler drum, this switch turns off the heater if there is no water in the drum. For other tanks these switches are used to prevent the pumps from running dry if there is nothing to pump into the tanks.c. High level switches provided at the cold water and hot water tanks to avoid the.