Plant Control Automation of Biogas Plants
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1 Plant Control Automation of Biogas Plants 1 st Biogas Training Days Bangkok, June 09 th 11 th 2014 Christian Etzkorn Folie 1
2 Agenda AWITE Bioenergie GmbH & TDI Automation basics Process control concepts Plant Safety Remote Control Process control & stabilization Demand based production Logging, reporting, efficiency and cost control It s time for you to take control. Manual vs. Automation Hands-on Training Folie 2
3 Company history Foundation first analysis system for H 2 S- measurement in biogas First Office With integrated manufacturing (~20 m² New Office New office building erected (700m²) 1000 Analysis Systems AwiFLEX Cool Analysis Systems 1650 Analysis Systems >100 Automation Systems 35 Employees Gas Analysis Systems Automation Measurement Technology Folie 3
4 Local Partner in Thailand: TDI Philosophy ; Biogas Equipment Expert 1994 Company Establish Research project at the Thailand & Germany Sale, Service and Development Equipments for Asia 2015 New office building, 1600m² Gas Blower Gas Flow Meter Gas Analysis Systems Flame Arrester Flare Gas Automation System
5 Agenda AWITE Bioenergie GmbH & TDI Automation basics Process control concepts Plant Safety Remote Control Process stabilization Demand based production Logging, reporting, efficiency and cost control Manual vs. Automation It s time for you to take control. Hands-on Training Folie 5
6 Automation & Visualization of Biogas plants Automation = Equipping a device so that it works as intended in whole or in part, without the participation of people(din V 19233) Human Biogasplant operator Information- and communication system Automationsystem Measuring device Actor Biogasplant Input Technical process Output Folie 6
7 Automation & Visualization of Biogas plants Increasing of Safety Comfort Economy Understanding by Measuring and switching Visualisaton Alerting Archiving Transferring Folie 7
8 Automation & Visualization of Biogas plants Automation Automation uses sensors and actuators to carry out courses of actions automatically Automation technology is widely used in many industries, because: (1) It reduces the risk of malfunctions, accidents and the required manpower (2) Machines don t get tired, thus uninterrupted work is possible (3) Safety is improved because actions are carried out equally, independent of the number of repitions (4) Automated systems can be designed to operate in toxic / dangerous environments where people cannot (or only with great difficulties) (5) Precission requirements and complex tasks as well as the handling of heavy materials demand the use of machines anyway, automation helps to use the equipment efficiently Folie 8
9 Agenda AWITE Bioenergie GmbH Automation basics Process control concepts Plant Safety Remote Control Process stabilization Demand based production Logging, reporting, efficiency and cost control Manual vs. Automation It s time for you to take control. Hands-on Training Folie 9
10 Process Control Concepts Sensors Periphery (Coupler, PLC) Bus or Network Actors Process - Visualisation Processcontroller Datahandling Process control system: Multiple visualisations, Alert system, recording of data Folie 10
11 Process Control Concepts Sensors Periphery (Coupler, PLC) Buscontroller 1 Buscontroller 2 Bus or Network Actuators Process - Visualisation Processview 1 Processview 2 Processview 3 Processcontroller Different Couplers/Controllers possible Visualisation on different Computers possible Datahandling expandable Awicontrol Visualisiation-Server Datahandling Spreadsheets AwiView AwiMail (Modbus/TCP, Profibus, ) (Windows, Linux, ) (Reports, external Software, ) Folie 11
12 Hardware used Panel PC Ethernet Switch Internet Remote Maintenance SPS Gasanalyzer Folie 12
13 Sensors Pressure Switches Used for pump protection Switch (Hardwired) Analog output Folie 13
14 Sensors - Temperature Substrate and hot water Principle: change of resistance PT mA Transmitter Protection tube Folie 14
15 Sensors - Overfillprotection Overfillprotection (WHG) Principle: capacity change of electric field Cleaning required (sulfur) Folie 15
16 Sensors - Overfillprotection Why cleaning? Folie 16
17 Sensors Leakage/Limit switch Principle: conductivity Cleaning required Integrated Monitoring of cable break Folie 17
18 Sensors Gas analysis system Control and protection of CHP Efficiency control Monitoring of caloric value / energy Monitoring of biological processes / stability Folie 18
19 External sensors connected to gas analysis automatic calculation functions External sensors pressure temperature moisture flow etc. Calculation of caloric value energy flow compensation of temperature, pressure and moisture etc. Folie 19
20 Other important parameters Parameter Gas pressure Flow (Liquids) Weight Electrical power Example of use Detection of overfilling and loss of biogas through the security valve, switching off devices in case of underpressure, automatic flare control Control of pumping processes, dosing of (co)substrates, documentation of amounts, surveillance of pumps, mixing processes of liquids and solids Controlled dosage of solid substrates CHP control and surveillance, power control, accounting of energy production Folie 20
21 Sensors Flow meter Used for dosing Principle: Induktion Influenced by ammount of dry material Mount vertically Respect in-, and outflow zone Folie 21
22 Agenda AWITE Bioenergie GmbH Automation basics Process control concepts Plant Safety Remote Control Process stabilization Demand based production Logging, reporting, efficiency and cost control Manual vs. Automation It s time for you to take control. Hands-on Training Folie 22
23 Plant Safety Alarm Messages by / voice call / SMS User defined surveillance of devices / sensors / actors etc Automatic safety measures (e.g. switching of pumps, opening / closing of valves etc.) Documentation of all automatic and user actions Folie 23
24 Plant Safety Gasanalysis Detection of dangerous atmosphere / explosion prevention Detection of high H 2 S and low CH 4 contents for motor protection & monitoring of biology Automatic safety measures / emergency shutdown Automatic alarm message to operator Folie 24
25 Plant Safety - Redundancy! Defect Folie 25
26 Agenda AWITE Bioenergie GmbH Automation basics Process control concepts Plant Safety Remote Control Process stabilization Demand based production Logging, reporting, efficiency and cost control Manual vs. Automation It s time for you to take control. Hands-on Training Folie 26
27 Authentication Internal and external login possible Userlevel depending on account Folie 27
28 Structure of Visualisation Division into tabs, subtabs and windows Display of errors in errorlist Displaying of caption for a better overview Colored representation of Actors and pump-ways Folie 28
29 Sensors and actors Usage of symbols for P&I schemes according to EN ISO Status of actors shown with different colors Folie 29
30 Central drop-down menu Handling of actors with the drop-down menu Folie 30
31 Faceplates Detailed information and handling in faceplates Folie 31
32 Errorlist Divides Errors into - actual and not acknowledged - actual but acknowledged - not actual anymore but not yet acknowledged Folie 32
33 Monitoring Generates errors when certain criterias are exceeded Relevant automatic actions will be stopped Folie 33
34 Intervals Differentiation Interval actons, two-step control, dosage actions Startdelay Activity Pause Duration of Interval Folie 34
35 Two-step control Differentiation Interval actons, two-step control, dosage actions Level Level Folie 35
36 Dosage Differentiation Interval actons, two-step control, dosage actions Folie 36
37 CHP State of CHP Relevant values and signals Folie 37
38 CHP Different possibilities of setpoint selection Automatic adjustment of setpoint according to gas level Linear setpoint control: Selection of minimum and maximum gaslevel for control Selection of minimum and maximum setpoint for CHP Linear adjustment between boundaries Folie 38
39 CHP Step control of CHP setpoint: Definition of thresholds for gas level and according setpoint of CHP Folie 39
40 Mobile phone visualization Folie 40
41 Agenda AWITE Bioenergie GmbH Automation & Visualization systems for biogas plants Process control concepts Plant Safety through Automation Remote Control Process stabilization Demand based production Logging, reporting, efficiency and cost control It s time for you to take control. Manual vs. Automation Hands-on Training Folie 41
42 Process Control Why? Folie 42
43 Approach: mathematical simulation models Folie 43
44 Approach: Fuzzylogic for plant control Folie 44
45 Agenda AWITE Bioenergie GmbH Automation basics Process control concepts Plant Safety Remote Control Process stabilization Demand based production Logging, reporting, efficiency and cost control Manual vs. Automation It s time for you to take control. Hands-on Training Folie 45
46 Demand based electricity production Gateway Panel PC CHP PLC Folie 46
47 Agenda AWITE Bioenergie GmbH Automation basics Process control concepts Plant Safety Remote Control Process stabilization Demand based production Logging, reporting, efficiency and cost control Manual vs. Automation It s time for you to take control. Hands-on Training Folie 47
48 AwiView 2.0 Transfer data from AwiFLEX / AwiControl Visualisation of data Display and evaluation of data in tables Dataexport Folie 48
49 Graphs Folie 49
50 Tables Folie 50
51 Events and Errors Folie 51
52 Export Folie 52
53 Reports Folie 53
54 Agenda AWITE Bioenergie GmbH Automation basics Process control concepts Plant Safety Remote Control Process stabilization Demand based production Logging, reporting, efficiency and cost control Manual vs. Automation It s time for you to take control. Hands-on Training Folie 54
55 Manual versus Automatic plant control Manual Lower investment costs If labour costs are low, manual operation is considered cheaper Simple biogas systems lack sensors and electrical components that could be automated Automatic Complex processes and operations need observation of many parameters at the same time computers are designed to do that Automation systems work 24/7 and react fast and automatically to unwanted situations If substrates need to be purchased (e.g. napier grass), plant efficiency becomes an issue automation systems are designed to provide high efficiency -> increase of revenue! Automation systems with remote control option allow the access of external experts at all time, so malfunctions and critical situations can be resolved better Folie 55
56 ขอขอบค ณ Vielen Dank Thank you Awite Bioenergie GmbH Grünseiboldsdorfer Weg Langenbach/Niederhummel Folie 56
57 Agenda AWITE Bioenergie GmbH Automation basics Process control concepts Plant Safety Remote Control Process stabilization Demand based production Logging, reporting, efficiency and cost control Manual vs. Automation It s time for you to take control. Hands-on Training Folie 57
58 ID 869 Thai San Miguel Liquor Application: Planning: Country: Sales: Wastewater to Biogas Thai San Miguel Liquor Co. Ltd Thailand Thai Daiichi Intertrade Co. Ltd 2010 Test Points: Sensors: Interfaces: Special Features: 1 CH4 O2 - H2S ppm Ethernet Analog 4 20 ma External gascooling
59 ID 891 Chumphon Application: Power: CDM 2,8 MW Endress & Hauser Planning: Country: Sales: Special Features: GmbH & Co KG Thailand AWITE CDM, embedded system 2010 Test Points: Sensors: Interfaces: Special Features: 1 CH4 CO2 Ethernet USB RS485 Continuous measurement, Automatic calibration
60 ID 1191 Es Bioenergy Application: Country: Sales: Wastewater to Biogas Thailand Thai Daiichi Intertrade Co. Ltd Test Points: Sensors: 1 CH4 CO2 - O2 H2S ppm Interfaces: Analog ma - USB
61 ID 1248 Eastern Palm Oil Application: Country: Sales: Biogas Thailand Thai Daiichi Intertrade Co. Ltd. Special Features: Biogas from Palm Oil Waste 2012 Test Points: Sensors: 1 CH4 - O2 H2S ppm Interfaces: Analog ma - USB
62 ID 1469 Khon Kaen sugar industry public company limited Application: Country: Sales: Wastewater to Biogas Thailand Thai Daiichi Intertrade Co. Ltd Test Points: Sensors: 1 CH4 - CO2 - O2 H2S ppm Interfaces: Ethernet - USB
63 ID 1474 Chanthaburi Starch Application: Country: Sales: Wastewater to Biogas Thailand Thai Daiichi Intertrade Co. Ltd Test Points: Sensors: Interfaces: 1 CH4 O2 - H2S ppm USB
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