Development of programmable logic-controller for peat water treatment

Transcription

1 Proceeding of ISBN nd International Conference on Sustainable Energy Engineering and Application Grand Hotel Preanger, Bandung, Indonesia October 2014 Development of programmable logic-controller for peat water treatment based AOP+RO Arjon Turnip a, *, Sutrisno Salomo Hutagalung b a Technical Implementation Unit for Instrumentation Development, Indonesian Institute of Sciences, Bandung, Indonesia b Center for Research and Development of Calibration, Instrumentation, and Metrology, Indonesian Institute of Sciences, Serpong, Indonesia Abstract This paper presents design and application of automatic control system in the peat water treatment system with Advanced Oxidation Process (AOP) and Reverse Osmosis (RO) method using a programmable logic-controller (PLC) unit. All electronic circuits and the necessary software for supporting a PLC unit have been designed and developed for controlling and monitoring a mechanical movement of the pump, electric control valve, and ozone generator. The PLC collects and stores related data to ph, level, conductivity, and flow of the treated water. It is found that the developed controller is properly running by which the system operational becomes easier, safer, and faster. The automatic control system also can be employed as a standalone device and can be connected to a personal computer through the RS232 serial port to monitor the whole process on a computer screen. Keywords: automatic control; peat water; PLC; AOP and RO method. Selection and/or peer-review under responsibility of Research Centre for Electrical Power and Mechatronics, Indonesian Institute of Sciences 1. Introduction Indonesia has 26 million hectares of peat land area, and a fourth country in the world which has the largest peat land in the world after Canada, Russia and the United States [1-3]. There are approximately 6 million hectares of peat land in Kalimantan with a thickness varying from 0.3 m to 20 m. Natural lowland tropical peat lands are dominated by trees (peat swamp forest) and are important reservoirs of biodiversity, carbon, and water. Indonesia has about 12.60% of peat forest and only about 0.2% of which can be used as a source of clean water. Water in peat areas has characteristic brownish red color, a relatively high content of mineral salts, such as Fe ions, sour taste with a ph of 3 5 [3]. Referring to clean water standards as written in the Permenkes, it is not feasible to consume the peat water for daily life due to the value of chemical and physical properties which out of the threshold value [4]. To be able to use the peat water as clean water, it needs to be processed first. One of the peat water treatment methods that can be used is the method of Advanced Oxidation Processes (AOP) and Reverse Osmosis (RO). AOP method is a method to destroy pollutants in water by oxidizes pollutants compounds into compounds that are not harmful to humans and the environment [5]. While the method of Reverse Osmosis (RO) is a filtration method to remove solid particles dissolved in water so that the water can be produced with good quality [6]. In the first phase of this research activity has been successfully created peat water processing system with AOP method. This system works well and is able to produce water based on water quality standards. However, this system is still limited with manually controller. Therefore, to improve the operational reliability of the developed peat water treatment system, an automatic controller system based on a programmable logic controlling unit is proposed. The PLC is chosen due its advantages such as robustness, high degree of scalability, extensibility, the ability to communicate sophisticated, and powerful development environment [7]. A suitable controlling program was also developed to accomplish the control * Corresponding author. Tel.: ; fax: address: arjon.turnip@lipi.go.id Indonesian Institute of Sciences, Research Centre for Electrical Power and Mechatronics Available online at

2 114 A. Turnip and S.S. Hutagalung / Proceeding of ICSEEA (2014) operation with the possibility of implementing this arrangement as a data-acquisition system for some physical values during water treatment process. 2. Method The developed controller system for peat water treatment using PLC system consists of five main parts which are PLC, sensors and actuators, AOP and RO, power supply, and softwares systems. The PLC hardware itself consist of [8, 9]: Control Processing Unit type CJ1M-CPU11-ETNUC, 160 E / S max., 100 Base-TX. Port Ethernet + RS-232C port; Power Supply Type CJ1W-PA ~ 240 Vac, 50/60 Hz, 50 VA; Digital Input Type CJ1W-ID211 / 16 point, 24 Vdc / 7 ma; Digital Output Type CJ1W-OD211 / 16 point, 24 VDC / 500 ma; Analog Input and Analog Output Type CJ1W-DA041 / 4 Chann., 4 ~ 20 ma / 1 ~ 5 Vdc; PSU and CPU modules, input/output modules; and digital input/output analog. Digital input are used to detect 10-contact status, and digital-output switch is used for command On/Off of the: pump motor, oxygen generator unit, and RO units. Analog input are used to detect the signal from the flow transmitter (FT), the level transmitter (LT), ph, and conductivity. Analog output has function to drive the Electric Control Valve (ECV) proportionally. In addition to digital and analog signal processing, the PLC can also convert analog signals to engineering units, methods of control variables with PID (proportional, integral, derivative) and TPO (time-proportional output). Fig. 1 shows the PLC installation in the main panel. Fig. 1. Installation of PLC hardware To support the PLC development to operate peat water processing systems, instrumentation components (i.e., Liquid level transmitter, Liquid Control Valve, Liquid Flow Indicator, Conductivity transmitter, ph transmitter, UV lamp, ozon generator, Pump, Electric Control Valve, DC Power supply Ip. 220 Vac/50 Hz, Op. 24Vdc/4,2 A, DC Power supply Ip. 220 Vac/50 Hz, Op. 12Vdc/8,5 A, cconverter RS232 to USB, and instrument assessories) are used. The designed controller and automatic monitoring system configuration as shown in Fig. 2 consists of PLC, desktop computers, notebook computers, and 4-port fast ethernet connected to each other via LAN [10-12]. Blue line shows the PLC connection to the actuator, the green line shows the connection of PLC to sensors and the red line indicates the PLC connection to the computer. Fig. 3 and Fig. 4 show the scheme and developed peat water treatment system integrated the developed PLC with AOP and RO method, respectively. The weight of the integrated AOP and RO system is about 400 kg (empty) and 800 kg (full with processed peat water). The ozonization consist of two tube: Tube 1 is equipped with a UV tube covered by black evasion for safety and transparant Tube 2 (i.e., treated water can be observed during the purification process). The ozonization itself depend on the effectiveness of the ozone reaction with peat water which can be achieved by extending the direct contact between the ozone and water peat. To achieve those direct contact, the plug flow equipped with a static mixer is applied. While ph and liquid height in the tank was kept constant with sediment through PLC system. The PLC electronic system consists of: PA-202; CJ2M-CPU31 + Ethernet / IP ports; EN-211/16-channel; OD-211/16- channel; AD041-V1/4-channel single-ended; and DA041/4-channel single-ended modules; a power-supply circuit, a digital input/output, and an analog input/output. The scheme of the PLC electronic are shown in Fig. 5. The power supply is divided into three parts, namely a voltage of 220 Vac, 24 Vdc and 12 Vdc. The 220 Vac voltage is distributed to the PLC, oxygen generators, ozone generators, motors pumps, UV lights, electric valve and RO system. The voltage of 24 Vdc is used for circuit input/output device of the PLC. While the 12Vdc voltage used for sensors and other fields. Human Machine Interface (HMI) computer is used to operate the AOP-RO based process system. The HMI consists of an interactive program i.e., animation process, the setup parameters, system diagnostics process, and trending/logging. Through the HMI computer, the peat water treatment process can be controlled, monitored, and analyzed in easier, faster, and higher accuracy. Notebook computer as an engineer work station is used as a PLC program development and diagnostic programs [13-15]. Discrete data access and variable-process between HMI and PLC communication is performed through EtherNet / IP with 10/100 Mbps speeds. HMI software is made using Kingview software Ver. 6:53 with type Kingview Development Full International Conference on Sustainable Energy Engineering and Application (ICSEEA) Grand Hotel Preanger, Bandung, Indonesia, October 2014

3 A. Turnip and S.S. Hutagalung / Proceeding of ICSEEA (2014) Edition: 64 tag-name incl. The HMI program consists of five sub-programs as follows: Animation of AOP and RO process program display peat water treatment process as a whole; Trend Monitor program displays an on line tendency graph of process variables in a given time; Reporting program serves as publisher and information storage processes, consists of 3 parts, namely; Alarm Monitor tables, water level setting graphs and dynamic ph adjusting charts; Diagnostic system program serves to verify the signal input / output discrete and signal input / output analog devices according identification (tag name) concerned. Parameter setting program is used for presetting the parameters into the PLC memory controller. 3. Results The calibration of the developed system is used to verify program function by entering analog input process variables. The result is then processed in the PLC memory and displayed in the HMI display. The calibration in this research including Liquid Level Transmitters, Liquid Control Valve, ph, conductivity and Liquid Flow Indicator. The calibration results can be seen in the Tables 1-5. Table 1. Level data in sediment tank. No Table 2. ph data of the reservoir 2. Table 3. Test data of conductivity reservoir 2. Table 4. Flow data of RO output. Water level in process tank 1 (cm) Level reading on HMI Output Value (ma) No Buffer ph ph reading on HMI Output Value (ma) No Standard Solution (us) Conductivity reading on HMI Output Value (ma) No Standard Solution (us) Flow reading on HMI Output Value (ma) Table 5. Test data of percentage opening of ECV. No Percentage opening on HMI Setting on PLC PLC Vo drive V dc Opening scale Indonesian Institute of Sciences, Research Centre for Electrical Power and Mechatronics

4 116 A. Turnip and S.S. Hutagalung / Proceeding of ICSEEA (2014) The real field tests are conducted to prove that the design results perform as expected. Electronic systems testing mainly emphasized the functional and operational security in the field. Functional testing is performed to determine whether the electronic components that are used and the programs that have been made properly work. Operational security testing is performed to determine the security aspects of the system operational to operators and the environment. The test program function verification for signal input / output discrete results are read by the PLC and HMI memory. Tuning parameters for PID control is directly related to the level of stability and the output speed of the requested clean water (monitored by using a flow meter). PID tuning parameters to control + TPO directly related to the ph stability the water quality standards. Conductivity related to the conductivity of water by which the alarm signal will be generated when the conductivity values are abnormal or outside the water quality standards. Fig. 2. AOP-RO process control and monitoring system design configuration Remarks: 1 peat water tank, 2. transfer pump, 3 ECV, 4. Rotameters, 5. Injector, 6. Static mixer, 7. Oxygen generator, 8. Ozone generator,.9 Flowmeter, 10.ozonation tank, 11. Destructor vent, 12. UV lamp, 13. Tank sediment, 14. Resevoir 1, 15. Active filter, 16. Reservoir 2, 17. Tank alum, 18. RO Pump, 19. RO Membrane, 20. microfilter, 21. Fresh water Fig. 3. Schema of peat water treatment system with AOP and RO method International Conference on Sustainable Energy Engineering and Application (ICSEEA) Grand Hotel Preanger, Bandung, Indonesia, October 2014

5 A. Turnip and S.S. Hutagalung / Proceeding of ICSEEA (2014) Ozonisation Tube + UV Ozonisation Tube Main Panel Fresh Water Valve Ozon Panel Indicator Panel Ozone Pump Reservoir 2 HMI Monitor Transfer Pump Fig. 4. Peat water treatment system with AOP and RO method Fig. 5. Power supply circuit diagram Automatic control system that has been created was tested its performance in processing peat water. The results show that the automatic control system works well. Sensors are capable on measuring physical parameters as expected. Switches and buttons also work well according to the design. Operational switches, pumps and valves is done automatically based on the program created and well work in accordance with the diagram of the process without any time delay. Peat water treatment process with AOP + RO method is running well. After the raw materials supplied to the system, ozone generator is automatically work. Then peat water and ozone are mixed to form a mixture of fluid and gas. The homogeneity of the mixture water increases with the static mixer containing a spiral-shaped plug flow. The mixture fluid entering the ozonization tank, the ultraviolet light 1 is automatically activated. By activation of the ultra-violet lamp, ozone molecules will be separated and the occurred formation of the hydroxyl radical OH will oxidize peat water to reduce pollutants in the water. After passing the ozonization in the tank 1 then the processed water will entering the ozonation in the tank 2 with the same proceses in the tank 1 so that decomposition process of pollutant compounds become more perfect. The fluid is then entered into carbon filter to filter pollutants and eliminates odor compounds in water pollutants. The treated water is tested and compared with the water quality standards. To obtain the drinking water quality, the treated water then filtered using a high-pressure RO to remove dissolved particles. All these processes run automatically wherein the actuator operation performed by the PLC. Peat water treatment processes (i.e., animation process, trend monitoring, reporting and diagnostic) that occur can be observed through the HMI screen as well. Indonesian Institute of Sciences, Research Centre for Electrical Power and Mechatronics

6 118 A. Turnip and S.S. Hutagalung / Proceeding of ICSEEA (2014) Animation is the water treatment process of AOP and RO including flow direction, On / Off pump motor, proportional valve (ECV), electric valve (E-VALVE), water level in the tank reactor and ozonation sediment tank, set point level and water level indicator (cm), the set point ph and the ph indicator, the indicator conductivity (us), and flow rate indicator output (liter / minute). Trend graph display consists of four parts: the water level in the tank sediment surface with a range from 0.0 to cm, the ph of the water in the tank recervior-2 with a range of 0-14 ph, conductivity of water in the tank recervior-2 with a range from 0.0 to 5000 us, the water flow rate in the pipe RO output with a range from 0.0 to 20 liters / min. Sub menu reporting program serves as publisher and information storage processes, consists of three parts: Alarm Monitor tables, charts, and setting the level of the graph dynamically adjusting the ph. Table alarm-event contains information about identification devices (tag name), date of event (event date), time of event (event-time), the limit value (limit-value), the type of incident (event-type) and the type of alarm (alarm-type). Sub menu system diagnostic program consists of three parts diagnostic programs, i.e discrete input, discrete output, analog input, analog output, PID Control and PID Control + TPO. Sub-program menu parameter settings used for presetting the parameters into the PLC memory controller. Facilities of this program to help engineers make the tuning parameters PB (Proportional-band), I (Integration time), D (Derivative-time), Ts (Time-sampling) for PID control, and tuning parameters of Tc (Time-period), OLL (lowerlimit output), OUL (output upper-limit) for TPO control, calibration or recalibration process variables. All the menu on the HMI were tested and able to work well in which menus are able to work in accordance with the design and function properly. There is no crash or program failure during the testing process. With the HMI, the operating system becomes much easier and controlled. The display menu of the HMI screen system are shown in Figs Fig. 6. Animation process program Fig. 7. Display of trend monitor level variables, ph, conductivity and discharge graphics International Conference on Sustainable Energy Engineering and Application (ICSEEA) Grand Hotel Preanger, Bandung, Indonesia, October 2014

7 A. Turnip and S.S. Hutagalung / Proceeding of ICSEEA (2014) Fig. 8. Display of alarm events menu, and dynamic ph level settings program Fig. 9. Display of system diagnostic program Fig. 10. Display of the parameter setting program Indonesian Institute of Sciences, Research Centre for Electrical Power and Mechatronics

8 120 A. Turnip and S.S. Hutagalung / Proceeding of ICSEEA (2014) Conclusions Peat water treatment with an automatic control system provides several advantages: first, the system is able to control the developed water treatment system in properly. The treated water was well separated from organic and inorganic compounds in the peat water (satisfy with water standard quality. Second, the system is able to provide the entire data used in the water supply plant. Third, the controlling and recording the contact time data required in the optimization of water treatment systems is achieved. Fourth, process automation has the ability to perform repetitive calculations and save the results in a database format that is useful for surveillance. This technique is proven has The ability to reduce time and effort in operating of peat water treatment system by considering safety and reliable-effective technology is proven. Acknowledgements This research was supported by the competitive program (No ) through the Research Center for Economic, supporting facilities by Research Center for Calibration, Instrumentation and Metrology, and the Bandung Technical Management Unit for Instrumentation Development (Deputy for Scientific Services), funded by Indonesian Institute of Sciences, Indonesia. References [1] H.M. Wöstena,,, E. Clymansa,S.E. Pageb,J.O. Rieleyc,S.H. Limind. Peat water interrelationships in a tropical peatland ecosystem in Southeast Asia. CATENA,Hydropedology: Fundamental Issues and Practical Applications. Volume 73, Issue 2, 15 April 2008, Pages [2] Aziz, H., Bukasir, YP, and Puryanti, D. 2007, "Peat Swamp Water Filtration with perlite-alloy Whereas Cretaceous". J. Research Chemicals. Vol ISSN: X. September [3] D Anwar Musadad. Peat Water Influence on Health and effort to Problem Solving. Health Research and Development Media. Vol VIII No [4] PERMENKES, KEP 907/MENKES/SK.VII, Drinking Water Standard, [5] Roberto Andreozzi, Vincenzo Caprio, Amedeo Insola, Raffaele Marotta, Advanced oxidation processes (AOP) for water purification and recovery. Catalysis Today 53 (1999) [6] Lilian Malaeb, George M. Ayoub. Reverse Osmosis Technology for Water Treatment: State of The Art Review. Desalination, Volume 267, Issue 1, 1 February 2011, Pages 1-8. [7] W. Bolton. Programmable Logic Controllers (Fourth Edition). Newnes. Oxford [8] Technical Manual, SYSMAC CJ-Series Analog I/O unit, OMRON Co., Japan,2009. [9] Technical Manual, SYSMAC CJ-Series Discrete I/O Unit, OMRON Co., Japan, [10] M. G. Ioannides, Design and Implementation of PLC-Based Monitoring Control System for Induction Motor, IEEE Transactions on Energy Conversion, 19, No:3 USA, 2004 [11] Ahmad Fouad Alwan, Fundamentals of Programmable Logic Controller - PLC, 1st Edition, Dar Al-Uns for Printing and Publishing and Distribution, Damascus, Syria.S, [12] S. Peng, M. C. Zhou, Ladder Diagram and Petri-Net-Based Discrete-Event Control Design Methods, IEEE Transactions on Systems, Man, and Cybernetics- Part C, Applications and Reviews, Vol.34 No.4 Nov pp [13] Technical Manual, Panel Computer & HMI; CE-base SCADA HMI, RoHS Co., USA, [14] L. Wang, K. Liu, Improvement of power factor and voltage for renewable energy systems using PLC's new fuzzy module, Circuits and Systems, Proceedings. The 2004 IEEE Asia-Pacific Conference on Volume 2, 6-9 Dec Page(s): vol.2 [15] M. Ogawa and Y. Henmi, Recent Developments on PC+PLC based Control for Systems, Brewery Process Automation Applications, Korea Beer, SICE-ICASE International Joint Conference 2006 Oct , 2006 in Bexco, Busan International Conference on Sustainable Energy Engineering and Application (ICSEEA) Grand Hotel Preanger, Bandung, Indonesia, October 2014